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The Six Sigma Handbook, Revised and Expanded, 2nd Edition

Book Description

The most comprehensive Six Sigma reference available, now revised and expanded

Completely rewritten and reorganized, this second edition of The Six Sigma Handbookcovers all the basic statistics and qualityimprovement tools of the Six Sigma quality management system. This new edition reflects the developments in Six Sigma over the past few years and will help maintain the book's position as the leading comprehensive guide to Six Sigma.

Key changes to this edition include:

  • New chapters on DFSS (Design for Six Sigma); Minitab, the most popular statistical software for Six Sigma; Six Sigma philosophy and values; flowcharting; and SIPOC
  • Coverage of the core problem-solving technique DMAIC (Define, Measure, Analyze, Improve, Control)
  • Dozens of downloadable, customizable Six Sigma work sheets
  • New material on important advanced Six Sigma tools such as FMEA (Failure Mode and Effects Analysis)

Table of Contents

  1. Copyright
  2. Preface
  3. Introduction
  4. Six Sigma Implementation and Management
    1. Building the Six Sigma Infrastructure
      1. WHAT IS SIX SIGMA?
      2. IMPLEMENTING SIX SIGMA
      3. BLACK BELTS
    2. Six Sigma Goals and Metrics
      1. ATTRIBUTES OF GOOD METRICS
      2. SIX SIGMA VERSUS TRADITIONAL THREE SIGMA PERFORMANCE
      3. THE BALANCED SCORECARD
      4. STRATEGY DEPLOYMENT PLAN
      5. INFORMATION SYSTEMS REQUIREMENTS
      6. DASHBOARD DESIGN
      7. SETTING ORGANIZATIONAL KEY REQUIREMENTS
    3. Creating Customer-Driven Organizations
      1. ELEMENTS OF CUSTOMER-DRIVEN ORGANIZATIONS
      2. SURVEYS AND FOCUS GROUPS
      3. CALCULATING THE VALUE OF RETENTION OF CUSTOMERS
      4. KANO MODEL OF CUSTOMER EXPECTATIONS
      5. QUALITY FUNCTION DEPLOYMENT (QFD)
      6. THE SIX SIGMA PROCESS ENTERPRISE
      7. USING QFD TO LINK SIX SIGMA PROJECTS TO STRATEGIES
      8. LINKING CUSTOMER DEMANDS TO BUDGETS
    4. Training for Six Sigma
      1. TRAINING NEEDS ANALYSIS
      2. THE STRATEGIC TRAINING PLAN
    5. Six Sigma Teams
      1. SIX SIGMA TEAMS
      2. PROCESS IMPROVEMENT TEAMS
      3. WORK GROUPS
      4. OTHER SELF-MANAGED TEAMS
      5. TEAM DYNAMICS MANAGEMENT, INCLUDING CONFLICT RESOLUTION
      6. FACILITATION TECHNIQUES
      7. TEAM PERFORMANCE EVALUATION
      8. TEAM RECOGNITION AND REWARD
    6. Selecting and Tracking Six Sigma Projects
      1. CHOOSING THE RIGHT PROJECTS
      2. ANALYZING PROJECT CANDIDATES
  5. Six Sigma Tools and Techniques
    1. Introduction to DMAIC and Other Improvement Models
      1. DMAIC, DMADV, AND LEARNING MODELS
    2. Problem Solving Tools
      1. PROCESS MAPPING
      2. FLOW CHARTS
      3. CHECK SHEETS
      4. PARETO ANALYSIS
      5. CAUSE AND EFFECT DIAGRAMS
      6. 7M TOOLS
      7. FULL ANALYTICAL CRITERIA METHOD
    3. Basic Principles of Measurement
      1. SCALES OF MEASUREMENT
      2. RELIABILITY AND VALIDITY OF DATA
      3. OVERVIEW OF STATISTICAL METHODS
      4. PRINCIPLES OF STATISTICAL PROCESS CONTROL
    4. Measurement Systems Analysis
      1. R&R STUDIES FOR CONTINUOUS DATA
      2. ATTRIBUTE MEASUREMENT ERROR ANALYSIS
    5. Knowledge Discovery
      1. KNOWLEDGE DISCOVERY TOOLS
      2. ESTABLISHING THE PROCESS BASELINE
      3. SIPOC
    6. Statistical Process Control Techniques
      1. STATISTICAL PROCESS CONTROL (SPC)
      2. EWMA
    7. Process Capability Analysis
      1. PROCESS CAPABILITY ANALYSIS (PCA)
      2. ESTIMATING PROCESS YIELD
    8. Statistical Analysis of Cause and Effect
      1. TESTING COMMON ASSUMPTIONS
      2. REGRESSION AND CORRELATION ANALYSIS
      3. ANALYSIS OF CATEGORICAL DATA
      4. NON-PARAMETRIC METHODS
    9. Managing Six Sigma Projects
      1. USEFUL PROJECT MANAGEMENT TOOLS AND TECHNIQUES
      2. PROJECT CHARTER
      3. WORK BREAKDOWN STRUCTURES
      4. FEEDBACK LOOPS
      5. PERFORMANCE MEASURES
      6. COST CONSIDERATIONS IN PROJECT SCHEDULING
      7. PROJECT MANAGEMENT IMPLEMENTATION
    10. Risk Assessment
      1. RELIABILITY AND SAFETY ANALYSIS
      2. FAILURE MODE AND EFFECT ANALYSIS (FMEA)
      3. STATISTICAL TOLERANCING
    11. Design of Experiments (DOE)
      1. TERMINOLOGY
      2. POWER AND SAMPLE SIZE
      3. DESIGN CHARACTERISTICS
      4. TYPES OF DESIGN
      5. EXAMPLES OF APPLYING COMMON DOE METHODS USING SOFTWARE
      6. EMPIRICAL MODEL BUILDING AND SEQUENTIAL LEARNING
      7. DATA MINING, ARTIFICIAL NEURAL NETWORKS AND VIRTUAL PROCESS MAPPING
    12. Maintaining Control After the Project
      1. BUSINESS PROCESS CONTROL PLANNING
      2. USING SPC FOR ONGOING CONTROL
      3. PROCESS CONTROL PLANNING FOR SHORT AND SMALL RUNS
      4. PREPARING THE SHORT RUN PROCESS CONTROL PLAN (PCP)
      5. PRE-CONTROL
    13. Design for Six Sigma (DFSS)
      1. PRELIMINARY STEPS
      2. DEFINE
      3. MEASURE
      4. ANALYZE
      5. DESIGN
      6. VERIFY
    14. Lean Manufacturing and Six Sigma
      1. INTRODUCTION TO LEAN AND MUDA
      2. WHAT IS VALUE TO THE CUSTOMER?
      3. WHAT IS THE VALUE STREAM?
      4. HOW DO WE MAKE VALUE FLOW?
      5. HOW DO WE MAKE VALUE FLOW AT THE PULL OF THE CUSTOMER?
      6. HOW CAN WE CONTINUE TOWARDS PERFECTION?
      7. BECOMING LEAN: A TACTICAL PERSPECTIVE
      8. SIX SIGMA AND LEAN
  6. Glossary of Basic Statistical Terms
  7. Area Under the Standard Normal Curve
  8. Critical Values of the t-Distribution
  9. Chi-Square Distribution
  10. F Distribution (α = 1%)
  11. F Distribution (α = 5%)
  12. Poisson Probability Sums
  13. Tolerance Interval Factors
  14. Durbin-Watson Test Bounds
  15. y Factors for Computing AOQL
  16. Control Chart Constants
  17. Control Chart Equations
  18. Table of d2* Values
  19. Power Functions for ANOVA
  20. Factors for Short Run Control Charts for Individuals, X-bar, and R Charts
  21. Significant Number of Consecutive Highest or Lowest Values from One Stream of a Multiple-Stream Process
  22. Sample Customer Survey
  23. Process σ Levels and Equivalent PPM Quality Levels
  24. Black Belt Effectiveness Certification
    1. [COMPANY] BLACK BELT SKILL SET CERTIFICATION PROCESS
    2. [COMPANY] BLACK BELT EFFECTIVENESS CERTIFICATION CRITERIA
  25. Green Belt Effectiveness Certification
    1. GREEN BELT SKILL SET CERTIFICATION PROCESS
    2. GREEN BELT EFFECTIVENESS CERTIFICATION CRITERIA
  26. AHP Using Microsoft Excel™
    1. Example
  27. References