© 2018 The Council for Six Sigma Certification. All rights ...

? 2018 The Council for Six Sigma Certification. All rights reserved.

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June 2018 Edition

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? 2018 The Council for Six Sigma Certification. All rights reserved.

Table of Contents

UNIT 1: INTRODUCTION TO SIX SIGMA .................................................................................................................. 6

CHAPTER 1: WHAT IS SIX SIGMA? .....................................................................................................................................6

Data Driven Processes and Decisions ....................................................................................................................6

Defining 6¦Ò ...........................................................................................................................................................7

Common Six Sigma Principles .............................................................................................................................10

Challenges of Six Sigma.......................................................................................................................................13

CHAPTER 2: SIX SIGMA HISTORY AND APPLICATION ............................................................................................................15

The Development of Statistical Process Control..................................................................................................15

Continuous Process Improvement: Toyota and Lean ..........................................................................................16

Motorola¡¯s Focus on Defects ...............................................................................................................................17

ABB, Allied Signal, and General Electric ..............................................................................................................18

Continued Growth of Six Sigma...........................................................................................................................19

Applying Six Sigma Knowledge ...........................................................................................................................20

CHAPTER 3: OTHER PROCESS IMPROVEMENT AND QUALITY METHODS...................................................................................23

Other Formal Quality or Process Improvement Programs ..................................................................................23

When to Use Six Sigma .......................................................................................................................................29

CHAPTER 4: LEAN CONCEPTS ..........................................................................................................................................30

The Seven Muda..................................................................................................................................................30

Other Forms of Waste .........................................................................................................................................38

Two Types of Muda .............................................................................................................................................39

5S ........................................................................................................................................................................39

Just-in-Time Manufacturing ................................................................................................................................41

CHAPTER 5: BASIC SIX SIGMA CONCEPTS ..........................................................................................................................43

Standard Deviation .............................................................................................................................................43

The Pareto Principle ............................................................................................................................................49

Voice of the Customer .........................................................................................................................................54

Basic Metrics .......................................................................................................................................................58

CHAPTER 6: APPROACHING THE PROBLEM ........................................................................................................................62

Problem Functions: y = f(x) ..................................................................................................................................62

The 5 Whys ..........................................................................................................................................................63

Creating a Problem Statement............................................................................................................................65

UNIT 2: PROJECTS AND PROCESSES...................................................................................................................... 70

CHAPTER 7: WHAT IS A PROCESS?...................................................................................................................................70

What is a Process? ..............................................................................................................................................70

Major Process Components ................................................................................................................................72

Process Owners ...................................................................................................................................................76

Data ....................................................................................................................................................................76

Defining Process Components: The SIPOC ..........................................................................................................76

Tips for a SIPOC Brainstorming Session ..............................................................................................................79

Sample SIPOC Diagrams......................................................................................................................................79

CHAPTER 8: QUALITY ....................................................................................................................................................85

Critical to Quality Characteristics ........................................................................................................................85

The CoQ and the CoPQ ........................................................................................................................................90

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? 2018 The Council for Six Sigma Certification. All rights reserved.

Quality is Critical to Success ................................................................................................................................95

CHAPTER 9: SELECTING THE RIGHT PROJECTS ....................................................................................................................96

Juggling the Right Amount of Projects ................................................................................................................96

Enterprise-Level Selection Process ......................................................................................................................96

See for Yourself .................................................................................................................................................105

CHAPTER 10: BASIC SIX SIGMA TEAM MANAGEMENT .......................................................................................................107

Building a Six Sigma Team ................................................................................................................................107

Timelines, Scheduling, and Milestones .............................................................................................................112

Budgets .............................................................................................................................................................116

CHAPTER 11: INTRODUCTION TO DMAIC AND DMADV ...................................................................................................118

DMAIC versus DMADV ......................................................................................................................................119

Define ................................................................................................................................................................121

Measure ............................................................................................................................................................122

Analyze ..............................................................................................................................................................123

Improve .............................................................................................................................................................124

Control ..............................................................................................................................................................125

Design ...............................................................................................................................................................125

Verify .................................................................................................................................................................126

Breaking up the Elephant ..................................................................................................................................127

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