© 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 ................................................................................................................ 11
CHAPTER 1: WHAT IS SIX SIGMA? ...................................................................................................................................11
Data Driven Processes and Decisions ..................................................................................................................11
Defining 6¦̉ .........................................................................................................................................................12
Common Six Sigma Principles .............................................................................................................................15
Challenges of Six Sigma.......................................................................................................................................18
CHAPTER 2: SIX SIGMA HISTORY AND APPLICATION ............................................................................................................20
The Development of Statistical Process Control..................................................................................................20
Continuous Process Improvement: Toyota and Lean ..........................................................................................21
Motorola¡¯s Focus on Defects ...............................................................................................................................22
ABB, Allied Signal, and General Electric ..............................................................................................................23
Continued Growth of Six Sigma...........................................................................................................................24
Applying Six Sigma Knowledge ...........................................................................................................................25
CHAPTER 3: OTHER PROCESS IMPROVEMENT AND QUALITY METHODS...................................................................................28
Other Formal Quality or Process Improvement Programs ..................................................................................28
When to Use Six Sigma .......................................................................................................................................34
CHAPTER 4: LEAN CONCEPTS ..........................................................................................................................................35
The Seven Muda..................................................................................................................................................35
Other Forms of Waste .........................................................................................................................................43
Two Types of Muda .............................................................................................................................................44
5S ........................................................................................................................................................................44
Just-in-Time Manufacturing ................................................................................................................................46
CHAPTER 5: BASIC SIX SIGMA CONCEPTS ..........................................................................................................................48
Standard Deviation .............................................................................................................................................48
The Pareto Principle ............................................................................................................................................54
Voice of the Customer .........................................................................................................................................59
Basic Metrics .......................................................................................................................................................63
CHAPTER 6: APPROACHING THE PROBLEM ........................................................................................................................67
Problem Functions: y = f(x) ..................................................................................................................................67
The 5 Whys ..........................................................................................................................................................68
Creating a Problem Statement............................................................................................................................70
UNIT 2: PROJECTS AND PROCESSES...................................................................................................................... 75
CHAPTER 7: WHAT IS A PROCESS?...................................................................................................................................75
What is a Process? ..............................................................................................................................................75
Major Process Components ................................................................................................................................77
Process Owners ...................................................................................................................................................81
Data ....................................................................................................................................................................81
Defining Process Components: The SIPOC ..........................................................................................................81
Tips for a SIPOC Brainstorming Session ..............................................................................................................84
Sample SIPOC Diagrams......................................................................................................................................84
CHAPTER 8: QUALITY ....................................................................................................................................................90
Critical to Quality Characteristics ........................................................................................................................90
The CoQ and the CoPQ ........................................................................................................................................95
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? 2018 The Council for Six Sigma Certification. All rights reserved.
Quality is Critical to Success ..............................................................................................................................100
CHAPTER 9: SELECTING THE RIGHT PROJECTS ..................................................................................................................101
Juggling the Right Amount of Projects ..............................................................................................................101
Enterprise-Level Selection Process ....................................................................................................................101
See for Yourself .................................................................................................................................................110
CHAPTER 10: BASIC SIX SIGMA TEAM MANAGEMENT .......................................................................................................112
Building a Six Sigma Team ................................................................................................................................112
Timelines, Scheduling, and Milestones .............................................................................................................117
Budgets .............................................................................................................................................................121
CHAPTER 11: INTRODUCTION TO DMAIC AND DMADV ...................................................................................................123
DMAIC versus DMADV ......................................................................................................................................124
Define ................................................................................................................................................................126
Measure ............................................................................................................................................................127
Analyze ..............................................................................................................................................................128
Improve .............................................................................................................................................................129
Control ..............................................................................................................................................................130
Design ...............................................................................................................................................................130
Verify .................................................................................................................................................................131
Breaking up the Elephant ..................................................................................................................................132
UNIT 3: ADVANCED DMAIC ................................................................................................................................ 133
CHAPTER 12: DEFINE ..................................................................................................................................................133
Creating a Project Charter ................................................................................................................................133
Project Ground Rules.........................................................................................................................................136
Define Toolset ...................................................................................................................................................137
Define Tollgate Checklist ...................................................................................................................................140
CHAPTER 13: MEASURE ..............................................................................................................................................143
Failure Modes and Effect Analysis ....................................................................................................................143
Collecting Data ..................................................................................................................................................145
Measure Tollgate Checklist ...............................................................................................................................160
CHAPTER 14: ANALYZE................................................................................................................................................161
Root Cause Analysis ..........................................................................................................................................161
Graphical Analysis .............................................................................................................................................165
Statistical Analysis ............................................................................................................................................172
Analyze Tollgate Checklist .................................................................................................................................174
CHAPTER 15: IMPROVE ...............................................................................................................................................175
Solutions Selection Matrix.................................................................................................................................175
Cost Benefit Analysis .........................................................................................................................................178
Piloting a Solution .............................................................................................................................................179
Planning Implementation..................................................................................................................................181
Improve Tollgate Checklist ................................................................................................................................182
CHAPTER 16: CONTROL ...............................................................................................................................................183
Revise FMEA ......................................................................................................................................................183
Create a Control Plan ........................................................................................................................................183
Visual Management ..........................................................................................................................................186
SPC Charts .........................................................................................................................................................186
Team Celebration and Reflection ......................................................................................................................189
Control Tollgate Checklist .................................................................................................................................189
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