You are previewing Continual Improvement Process.
O'Reilly logo
Continual Improvement Process

Book Description

Continual Improvement Process focuses on the continual improvement process, providing contemporary tools and methods for achieving optimum quality and process improvement. It is immensely practical for manufacturing, service, and non-profit enterpr

Table of Contents

  1. Cover
  2. Title Page
  3. Contents
  4. Dedication
  5. Preface
  6. SECTION A AN OVERVIEW
    1. CHAPTER 1 Total Quality Management with Six Sigma
      1. Total quality management—meaning
      2. TQM—eight fundamental principles
      3. Variation
      4. Six Sigma
      5. TQM vs. Six Sigma
      6. World trend in quality
      7. Conclusion
    2. CHAPTER 2 Continual Improvement and Competitive Edge
      1. Context of quality
      2. Expectations of the society
      3. Competitive edge
      4. Constituents of competitive edge
      5. Competitive edge—differentiations and distinctiveness
      6. Continual improvement—a larger perspective
      7. Conclusion
    3. CHAPTER 3 Basics of Continual Improvement Process
      1. Continual improvement
      2. Process and its potential
      3. Zero defect level
      4. Is zero defect level attainable?
      5. Improvement as ‘restoration’ and ‘breakthrough’
      6. Technology
      7. Tools and techniques
      8. Managerial practices
      9. Model
      10. Conclusion
      11. Annexure 3A: Tools for quality and their brief description
    4. CHAPTER 4 Process and Quality of Process
      1. SIPOC—a process model
      2. An overall understanding of continual improvement process
      3. Defect
      4. Sigma value of the process—a measure of quality
      5. Conclusion
      6. Annexure 4A: Guidelines on preparing defect checklist
  7. SECTION B SCANNING METHODOLOGY TO CLEAN-UP AND SANITISE A PROCESS—FIRST STEP TO CONTINUAL IMPROVEMENT
    1. CHAPTER 5 Process Analysis Against a Checklist of Process Requirements to be Met
      1. Background
      2. Checklist of requirements
      3. Screening/review of process
      4. Conclusion
      5. Annexure 5A
    2. CHAPTER 6 Process Analysis Through Flow Chart
      1. Flow chart: technique
      2. Flow chart: analysis
      3. Process-centred approach
      4. Conclusion
    3. CHAPTER 7 Process Analysis: Interfering Factors and Action
      1. Process interference
      2. Checklist of interfering factors
      3. Interferences: applicability and analysis
      4. Relevance to continual improvement project/problem
      5. Conclusion
    4. CHAPTER 8 Process Analysis for Defect Prevention
      1. Process review
      2. Reference base—listing for review of process
      3. Conclusion
      4. Annexure 8A Self-control: an evaluation as applicable to manufacturing
    5. CHAPTER 9 Process Analysis for Gaps in Specification
      1. Specification
      2. Gap analysis: listing of gaps in specification
      3. Conclusion
      4. Annexure 9A
      5. Annexure 9B
      6. Annexure 9C: Note on Juranian classification of quality needs
      7. Annexure 9D: Analysis of customer requirements and their seriousness
    6. CHAPTER 10 Process Analysis: Customer Interface
      1. Customer link
      2. Scrutiny of customer needs
      3. Customer interface
      4. Conclusion
    7. CHAPTER 11 Failure Mode Effect Analysis
      1. Background
      2. Purpose
      3. Meaning of FMEA
      4. Analysis
      5. Conclusion
      6. Annexure 11A
      7. Annexure 11B: Failure mode reference list
      8. Typical key words and phrases
  8. SECTION C MEASUREMENT OF PROCESS DEFECT LEVEL AND PROCESS CYCLE EFFICIENCY
    1. CHAPTER 12 Basics of Six Sigma Technique
      1. Background
      2. Thought process of Six Sigma
      3. Process, quality characteristic and specification
      4. Specification, variation, process capability
      5. Process capability and quality system
      6. Statistical control
      7. Normal law
      8. Specification, process capability, defects and key thoughts of Six Sigma technique
      9. Process capability and sigma value of the process
      10. Obtaining the Sigma value of a process:
      11. Obtaining the Sigma value of a process: z value from defect rate
      12. Illustrative examples: Calculating
      13. First time yield (FTY)
      14. First time yield and
      15. Rolled throughput of a process
      16. A note on
      17. Sustainability of improvement
      18. Application of Six Sigma tool
      19. Problem 1
      20. Normalized yield
      21. Process capability analysis (PCA)
      22. Conclusion
      23. Annexure 12A: Exercises on Six Sigma calculations
    2. CHAPTER 13 Improving Process Flow and Speed to Achieve Lean Process
      1. Background
      2. Process flow and process speed
      3. Checklist of factors having a bearing on process flow and speed
      4. Lean Six Sigma
      5. Addressing the factors of hold-up
      6. Process set-up
      7. Work in process, lead time and process cycle efficiency
      8. Conclusion
  9. SECTION D CONTINUAL IMPROVEMENT PROCESS FRAMEWORK
    1. CHAPTER 14 Organising for Continual Improvement
      1. Scope
      2. The big picture of continual improvement
      3. Strategy plan
      4. Statistical techniques—understanding their importance
      5. Micro-strategy
      6. Guidelines to project selection
      7. Authors’ observation on learning programmes
      8. Conclusion
    2. CHAPTER 15 Anchor Points of the Continual Improvement Thought Process
      1. Background
      2. Anchor points
      3. Conclusion
      4. Annexure 15A
      5. Annexure 15B
      6. Annexure 15C
    3. CHAPTER 16 Involvement of People in Continual Improvement Process
      1. Background
      2. Productivity
      3. Organising an enterprise
      4. Continual improvement and productivity in an organization
      5. Distinct features of a people-friendly environment
      6. Reality check: Involvement
      7. Impact of continual improvement
      8. Conclusion
      9. Annexure 16A
      10. Annexure 16B
      11. Annexure 16C
      12. Annexure 16D
      13. Annexure 16E
      14. Annexure 16F Supplier base management
      15. Annexure 16G
      16. Annexure 16H
    4. CHAPTER 17 Soft Skills for Effective Practice of Continual Improvement
      1. Background
      2. Communication
      3. Communication gap
      4. Violence in communication
      5. Meeting
      6. Impact on individuals
      7. Conclusion
    5. CHAPTER 18 Tools of Logical Thinking and Qualitative Analysis
      1. Background
      2. Quality thinking
      3. Tools of qualitative analysis
      4. Brain storming
      5. Conclusion
    6. CHAPTER 19 Tools and Techniques: Problem Solving Through Pattern Discovery and Probing
      1. Background
      2. Problem
      3. Pattern discovery and investigation route
      4. Data orientation
      5. Tools and techniques
      6. Frequency distribution/histogram
      7. Break even point
      8. Few approaches: critical incident analysis, engineering a failure and defect generation at levels that generate failures
      9. Benchmarking
      10. Conclusion
      11. Annexure 19A
      12. Annexure 19B
      13. Annexure 19C
      14. Annexure 19D
    7. CHAPTER 20 Problem, Data and Interpretation of Data
      1. Thought routine: problem and data
      2. Reality check: problem formulation
      3. A digression—reference to research in neurology on data
      4. Investigation
      5. Statistical linkage to investigation
      6. Data on results and data on process
      7. Statistical techniques
      8. Data: a macro view
      9. Conclusion
      10. Annexure 20A
  10. SECTION E STATISTICAL TECHNIQUES FOR INVESTIGATION AND IMPROVEMENT
    1. CHAPTER 21 Measuring System
      1. Importance of the measuring system
      2. Measuring system: Illustration
      3. Certain fundamental properties that define a ‘good’ measurement system
      4. Traceability
      5. Conclusion
      6. Annexure 21A: Frame work of a system of control on measurements and measuring devices
    2. CHAPTER 22 Measurement Process: Statistical Concepts
      1. Measurement system ‘ideal’ but measurements are not identical
      2. Pattern of variation: measurements
      3. Statistical properties of measurement data
      4. Measurement capability
      5. Relationship: product specification and process capability and measurement system
      6. Cause of bias/linearity, and inadequate repeatability and reproducibility
      7. Conclusion
    3. CHAPTER 23 Product/Process Comparison: Statistical Tests of Significance
      1. Statistical significance
      2. Conclusion
      3. Illustrative example 1
      4. Illustrative example 2
      5. Illustrative example 3
      6. Illustrative example 4
      7. Illustrative example 5
      8. Illustrative example 6
      9. Illustrative example 7
      10. Illustrative example 8
      11. Illustrative example 9
      12. Illustrative example 10
      13. Annexure
      14. Summary of statistical tests of significance
    4. CHAPTER 24 Analysis of Frequencies, Analysis of Variance, Regression and Correlation Analysis
      1. Analysis of frequency: illustration
      2. Analysis of variance (ANOVA): Comparison of averages of more than two samples, one way classification
      3. ANOVA: two-way classification
      4. Regression analysis
      5. Correlation analysis
      6. Conclusion
    5. CHAPTER 25 Technology Improvement: Application of Design of Experiments
      1. Statistics, a key technology
      2. Industrial experimentation
      3. Taguchi’s methods
      4. Principles of Taguchi’s methods
      5. Design of experiments
      6. An important observation
      7. Understanding OA design
      8. Standard OA designs and their linear graphs
      9. Steps in designing, conducting and analysing an experiment
      10. Analysis of experimental results: response by measurement (variable data)—Illustrative example 1
      11. Analysis of experimental results: response by attribute data—illustrative example 2
      12. Summary of results—average response of significant factors and interactions
      13. Conclusion
      14. Annexure 25A
  11. SECTION F CONTINUAL IMPROVEMENT—MANAGERIAL ASPECTS
    1. CHAPTER 26 Managing Continual Improvement Project
      1. Background
      2. Management commitment
      3. Training programmes
      4. Team building
      5. Continual improvement projects—classification
      6. Project team—route map for handling a project
      7. Database
      8. Overall assessments: continual improvement projects
      9. Common reasons for setback in CIP
      10. Key points to comply with for healthy environment
      11. Synergistic impact
      12. Conclusion
      13. Annexure 26A
      14. Annexure 26B
      15. Annexure 26C
      16. Annexure 26D
      17. Annexure 26E
    2. CHAPTER 27 Route Map for Handling a Project
      1. Background
      2. Discussion
      3. Route map—DMAIC
      4. Define stage
      5. Measure stage
      6. Analyse stage
      7. Illustrative example 1: feedback from outpatients
      8. Illustrative example 2: process speed investigation
      9. Improve stage
      10. Control stage
      11. Illustrative example 3: analysis of difficulties in the purchase department
      12. Assessment of each phase of DMAIC
      13. Continual improvement Six Sigma, jargons
      14. Conclusion
      15. Annexure 27A
      16. Annexure 27B
    3. CHAPTER 28 Continual Improvement: Service Sector
      1. Background
      2. Peculiarities—non-profit institution
      3. Peculiarities—service sector
      4. Service industry: few new features of competitive edge
      5. Training
      6. Areas of concern
      7. Conclusion
    4. CHAPTER 29 Animal World and Self-improvement
      1. Background
      2. Role model
      3. Conclusion
  12. SECTION G CONTINUAL IMPROVEMENT—LARGER VITAL ISSUES
    1. CHAPTER 30 Culture of Innovation and Improvement
      1. Background
      2. Vision—characteristic features
      3. Vision—illustrative examples
      4. Vision and institution
      5. Clear vision
      6. Entrepreneurship par excellence
      7. Ventures of Prof. P. C. Mahalanobis
      8. Recruitment—focus on the potential and not on track record
      9. Unorthodoxy
      10. Networking for brain irrigation
      11. An observation
      12. The
      13. An urgent task
      14. Conclusion
    2. CHAPTER 31 Environment for Continual Improvement Process—Organisational Practices
      1. Background
      2. A long journey
      3. Challenges ahead
      4. People—the nucleus of an institution
      5. Stephen Covey’s classification
      6. Managerial practices
      7. Institution and its individuals
      8. Conclusion
  13. SECTION H CONTINUAL IMPROVEMENT—STARTING OFF AND PRACTICAL HINTS
    1. CHAPTER 32 From Where to Begin?
      1. Background
      2. Outlook on housekeeping
      3. Benchmark
      4. Cardinal principles
      5. Issues covered
      6. Conclusion
    2. CHAPTER 33 Continual Improvement—Relevance to Individuals
      1. Background
      2. Individual and work
      3. Work and Improvement
      4. Conclusion
    3. CHAPTER 34 Epilogue
  14. Bibliography
  15. Notes
  16. Glossary
  17. Acknowledgements
  18. Copyright