Implementing Six Sigma: Smarter Solutions Using Statistical Methods: Second Edition » (2nd Edition)

Forrest W. Breyfogle III is the founder and President of Smarter Solutions, Inc., a company specializing in training andconsulting in Six Sigma methodologies. He is the author of Statistical Methods for Testing, Development, and Manufacturing and Implementing Six Sigma and coauthor of Managing Six Sigma, all published by Wiley.

Written to aid organizations in laying the foundation for Six Sigma, this comprehensive and engaging guide provides the tools, strategies, and motivation to get all relevant players involved with improvement from upper management on down. At the heart of the book is a group of statistical tools that address FMEA (Failure Mode and Effect Analysis), QFD (Quality Functional Deployment), and DOE (Design of Experiment).

Rather than offering just a brief overview, Implementing Six Sigma devotes individual chapters to all of the tools, so as to provide an in-depth analysis of each. A large selection of diagrams and clarifying exercises demonstrate how to best utilize the tools to successfully minimize defects throughout the production process. To provide a deeper understanding, the book discusses the theories of Edward Deming and the history of the Six Sigma program. Steeped in real world application, it presents numerous examples, as well as copies of actual implementation guides used by Motorola.

Ramon V. Leon Associate Professor, Statistics Department of the University of Tennessee Associate editor, Six Sigma Forum magazine -

"No other book covers-at an adequate technical level-as many topics important to Six Sigma. An indispensable reference for the Six Sigma practitioner."

PREFACE.

PART I: S⁴/IEE DEPLOYMENT AND DEFINE PHASE FROM DMAIC.

1. Six Sigma Overview and S⁴/IEEE Implementation.

2. Voice of the Customer and the S⁴/IEEE Define Phase.

PART II: S⁴/IEE MEASURE PHASE FROM DMAIC.

3. Measurement and the S⁴/IEEE Measurement Phase.

4. Process Flow Charting/Process Mapping.

5. Basic Tools.

6. Probability.

7. Overview of Distributions and Statistical Processes.

8. Probability and Hazard Plotting.

9. Six Sigma Measurements.

10. Basic Control Charts.

11. Process Capability and Process Performance Metrics.

12. Measurement Systems Analysis.

13. Cause-and-Effect Matrix and Quality Function Deployment.

14. FMEA (Failure Mode and Effects Analysis).

PART III: S⁴/IEE ANALYZE PHASE FROM DMAIC (OR PASSIVE ANALYSIS PHASE).

15. Visualization of Data.

16. Confidence Intervals and Hypothesis Tests.

17. Inferences: Continuous Response.

18. Inference: Attribute (Pass/Fail) Response.

19. Comparison Tests: Continuous Response.

20. Comparison Tests: Attribute (Pass/Fail) Response.

21. Bootstrapping.

22. Variance Components.

23. Correlation and Simple Linear Regression.

24. Single-Factor (One-Way) Analysis of Variance (ANOVA) and Analysis of Means (ANOM).

25. Two-Factor (Two-Way) Analysis of Variance.

26. Multiple Regression, Logistic Regression, and Indicator Variables.

PART IV: S⁴/IEE IMPROVE PHASE FROM DMAIC (OR PROACTIVE TESTING PHASE).

27. Benefiting from Design of Experiments (DOE).

28. Understanding the Creation of Full and FractionalFactorial 2^K DOEs.

29. Planning 2^K DOEs.

30. Design and Analysis of 2^K DOEs.

31. Other DOE Considerations.

32. Robust DOE.

33. Response Surface Methodology.

PART V: S⁴/IEE CONTROL PHASE FROM DMAIC AND APPLICATION EXAMPLES.

34. Short-Run and Target Control Charts.

35. Control Charting Alternatives.

36. Exponentially Weighted Moving Average (EWMA) and Engineering Process Control (EPC).

37. Pre-Control Charts.

38. Control, Plan, Poka-Yoke, Realistic Tolerancing, and Project Completion.

39. Reliability Testing/Assessment: Overview.

40. Reliability Testing/Assessment: Repairable System.

41. Reliability Testing/Assessment: Nonrepairable Devices.

42. Pass/Fall Functional Testing.

43. S⁴/IEEE Application Examples.

PART VI: S⁴/IEE LEAN AND THEORY OF CONSTRAINTS.

44. Lean and Its Integration with S⁴/IEEE .

45. Integrating of Theory of Constraints (TOC) in S⁴  /IEE.

PART VII: DFSS AND 21-STEP INTEGRATION OF THE TOOLS.

46. Manufacturing Applications and A 21-Step Integration of the Tools.

47. Service/Transactional Applications and A 21-Step Integration of the Tools.

48. DFSS Overview and Tools.

49. Product DFSS.

50. Process DFSS.

PART VIII: MANAGEMENT OF INFRASTRUCTURE AND TEAM EXECUTION.

51. Change Management.

52. Project Management and Financial Analysis.

53. Team Effectiveness.

54. Creativity.

55. Alignment of Management Initiatives and Strategies with S⁴/IEEE .

Appendix A. Supplemental Information.

Appendix B. Equations for the Distributions.

Appendix C. Mathematical Relationships.

Appendix D. DOE Supplement.

Appendix E. Reference Tables.

List of Symbols.

Glossary.

References. 

Index.