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

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

Harmony Living, LLC, 412 N. Main St, Suite 100, Buffalo, WY 82834

June 2018 Edition

Disclaimer: The information provided within this eBook is for general informational purposes only. While

we try to keep the information up-to-date and correct, there are no representations or warranties,

express or implied, about the completeness, accuracy, reliability, suitability or availability with respect to

the information, products, services, or related graphics contained in this eBook for any purpose. Any use

of this information is at your own risk.

The author does not assume and hereby disclaims any liability to any party for any loss, damage, or

disruption caused by errors or omissions, whether such errors or omissions result from accident,

negligence, or any other cause.

This is a free eBook. You are free to give it away (in unmodified form) to whomever you wish.

Page | 2

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

Using the most recent edition in your workplace?

Because we continually attempt to keep our Handbook up to date with the latest industry

developments, be sure to check our website often for the most recent edition at

.

Page | 3

? 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¦Ò .........................................................................................................................................................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

Page | 4

? 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

Page | 5

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

 ................
................

In order to avoid copyright disputes, this page is only a partial summary.

Google Online Preview   Download