Six Sigma Quality for Business and Manufacture

by Joseph M J Gordon

Overview

Six Sigma is Business and Industry's newest recognized quality program. This text provides information and instructions for new and current quality professionals in order to help employ methods to attain Six Sigma defect quality assurance within their company.All areas of business and manufacture are covered. Detailed checklists, questionnaires and forms assist personnel in developing their own programs to 'prevent' problems from occurring and to solve new and long-term problems in services and manufacturing. Examples and formulae are provided for use to determine if, when and then how much a process may be adjusted for reaching higher quality assurance levels. Knowledgeable readers will be able to use this comprehensive text immediately in the workplace.

Product Details

ISBN-13:	9780444510471
Publisher:	Elsevier Science
Publication date:	10/25/2002
Pages:	572
Product dimensions:	6.00(w) x 9.00(h) x (d)

Table of Contents

	Preface	v
	Acknowledgments	vii
Chapter 1.	How Companies Use Six Sigma to Improve Processes and Prevent Problems	1
	Programs That Can be Initiated	2
	Quality Implementation Tools	3
	Six Sigma Programs	3
	Six Sigma Risk and Fault Abatement	4
	Defect Reduction	5
	Where Can Six Sigma Breakthrough Occur	8
	Measure--Analyze--Improve--Control	11
	Program Analysis	13
	Check Lists for Six Sigma Analysis	14
	Selecting the Six Sigma Program	15
	Establish Quality Improvements	19
	Quality Function Deployment	21
	Six Sigma Program Implementation Guidelines	22
	Training	28
	Communication	30
	References	31
Chapter 2.	Six Sigma Implementation Process	33
	Rate of Six Sigma Implementation	40
	The Key is Managing for Six Sigma	40
	Designing for Six Sigma	42
	Processing for Six Sigma	43
	Rates for the Employment of Six Sigma Methodologies	44
	Establishing the Base Line for Six Sigma Improvement	45
	Determine Your Baseline Quality Level for Six Sigma Analysis	46
	Monthly Improvement Rate Significance for Change	50
	Quality Function Deployment	57
	Establishing QFD Operations	58
	Steps in the QFD Implementation Process	60
	QFD Analysis Conclusions	66
	Selecting Six Sigma Black Belt and Team Candidates	69
	Six Sigma Black Belt Selection	70
	Black Belts Embed Six Sigma Methods into Company Culture	77
	Selection of a Champion for Six Sigma Team Success	79
	Personnel Requirements	81
	Selecting Team Members	82
	Define Six Sigma Team Roles	83
	Quality Team Charter	84
	Team Member Task Assignments	90
	Company Departmental Organization and Responsibility	91
	Six Sigma Data Collection	93
	Establish Data Collection	93
	Training Options	95
	Technical Six Sigma Knowledge Required for Quality Improvement	97
	Goal Setting	97
	Planning and Implementation Processes	98
	References	98
Chapter 3.	Reasons for Implementing Six Sigma	99
	Contributor to Quality Example	99
	How Tight is Six Sigma Quality	100
	Initial States of Implementation of Six Sigma for Business and Manufacturing	101
	Anticipated Early Six Sigma Results	107
	Six Sigma Team Skills	107
	Problems Identified to Complexity	112
	Analysis of Complex Problems or Process Improvements	112
	How a Six Sigma Team Solved a Problem	113
	References	124
Chapter 4.	Design Your Operations for Six Sigma Manufacture	125
	Six Sigma Design Matrix	125
	Elimination of Seventy to Eighty Percent of Final Design Problems with Six Sigma	126
	Design Steps for Six Sigma Production	129
	Failure Mode and Effects Analysis (FMEA)	133
	Use of Check Lists for a FMEA	135
	Use of Trouble Shooting Guides for a FMEA	136
	FMEA Team Development	136
	Assumptions for the FMEA Process	139
	Manufacturing Cell Equipment and Operations	139
	Manufacturing Cell External Support Systems	140
	Supplier and Customer--Past and Future Requirements	140
	Maintenance One of the Keys to Six Sigma Quality Operation	141
	Preventative Maintenance the Company Goal	141
	Benefits to Company Production Schedule	143
	Use of the Maintenance FMEA	143
	Occurrence	146
	Detection for Prevention of Problems	148
	Predicative Methods	149
	Cause and Effect Analysis	149
	Example of Cause and Effect Analysis	150
	Example of Poor Lot Control	153
	Problem Analysis, Cause and Affect	154
	Final Analysis of the Problem	155
	Conclusion, the Prevention of a Problem	156
	Documentation	156
	Taking Action--What and How	158
	What Action Should be Taken?	158
	Corrective Action	159
	How is Action Taken	159
	Immediate Action	160
	Problem Solving Matrix	165
	Preventive Actions	167
	References	169
Chapter 5.	Six Sigma Education and Using the Existing Quality Methods and Procedures	171
	The Need for a Company Champion	173
	Categorize and Analyze Quality Problems	174
	Problem Solving Categories	176
	Conformance Problems	176
	Product Deviation Problem	179
	Engineering Change Request (ECR)	180
	Unstructured Performance Problems	184
	Efficiency Problems	185
	Six Sigma Goal Setting	186
	Product Design Problems	188
	Process Design Problems	189
	Tools for Implementing Six Sigma	191
	Process Mapping for Six Sigma Team Actions	192
	Profile Process Improvement	193
	Six Sigma Program Requirement Overview	196
	Six Sigma Team Training	197
	The Tools for Six Sigma Problem Solving and Prevention	199
	Statistical Process Control	200
	Process Control Charting	205
	Calibration	208
	How to Determine the Variables to Monitor	210
	Establishing Control Limits for the Process	211
	Determining the Critical Product Dimensions	212
	Process Control Charting	214
	Control Charts	215
	Measurement Process Control Chart Calculations	217
	Control Chart Calculation Procedure	222
	Control Limit Calculations	222
	Data Collection	227
	Who Should Collect the Data	230
	Data Presentation for Monitoring Control	232
	How Should Data be Used	232
	Who Uses the Data and When	234
	What to do When Out of Control Occurs	235
	Who Makes the Changes and What Changes are Made	235
	How Long to See the Effects of a Process Change	235
	Consider a DOE (Design of Experiments)	237
	Statistical Process Control for Complex Problems	239
	Statistical Process Control Charts	240
	Process Limits	241
	Data Subgroups	243
	Out of Control Situations	244
	References	245
Chapter 6.	Achieving an Effective Six Sigma Deployment Plan	247
	Selecting the Program for Six Sigma	247
	The Analysis of the Organization and Cost of Quality	249
	Cost of Quality Prevention Areas	249
	Cost of Quality for Six Sigma	250
	Prevention Versus Correction	253
	Appraisal Cost	253
	Calculating Cost of Product Quality	254
	Quality Return on Investment	260
	Deploy Six Sigma by Functional Area, Product, Process and Department	261
	Program Management Representatives	263
	Pareto Charts	263
	Standard of Flexible Implementation Design Across Varied Business Units	266
	ISO9000 Improvements Based on Six Sigma Results	266
	Balance the Rate of Deployment for Maximum Effectiveness	267
	Kaizen	268
	Six Sigma Programs	270
	Six Sigma Opportunities for Problem Prevention	271
	Reengineering Existing Infrastructure to Facilitate Six Sigma	275
	How to Balance the Rate of Deployment for Optimum Effectiveness	276
	Example of Change Correctly Implemented	276
	References	278
Chapter 7.	Six Sigma Improvements in Business and Manufacturing	279
	Obtain Improvements in Business and Manufacturing, Bench Marking and Indicators	279
	Software Systems for Six Sigma Quality	280
	Six Sigma (Business) Order Entry Software Requirements	281
	Manufacturing Data Entry	282
	Bar Code Tracking	282
	Benchmarking	283
	Six Sigma Impact on in Place Quality Systems	284
	Applying Six Sigma Tools for Continued Improvement	285
	Product Capability	286
	Fun and Enjoyment Implementing Six Sigma	288
	Testing	288
	Metric Example	288
	An Example of Problem Solving	289
	Process-Capability	291
	Process-Capability Index	295
	Types of Testing, Appraisal, Confirmation and Characterization	296
	Confirmation Testing	297
	Process Test Control (Destruction Test)	298
	Characterization Testing	299
	Confirmation	299
	Variance Ratio	300
	The Risk of Making a Bad Decision	302
	Tracking Manufacturing Using Existing Process Indicators	305
	Verification of Six Sigma Manufacturing Capability	306
	What Really is Six Sigma and Improved Process Control	307
	Six Sigma Methodology	309
	Implementing the Six Sigma Process	311
	Implementing the Six Sigma Improvement Program	312
	Six Sigma Program Development	317
	Six Sigma Pays Its Own Way	318
	Procedures for Implementing Six Sigma	320
Step 1	Assessment of the Company Organization	320
Step 2	Executive Action Planning Workshop	324
	Couple the Six Sigma Program to the Company Vision Statement	325
Step 3	Gathering Information	326
Step 4	Just-In-Time Training	328
	Optimization the Key to Achieving Six Sigma Capability	330
	References	330
Chapter 8.	Six Sigma Keys to Success are Control, Capability and Repeatability	333
	The Three Keys to Six Sigma Success	334
	Maintaining Process Control	334
	Measure, Analyze, Improve and Control the Process	335
	Example of Base Line Capability	336
	The Twelve Step Improvement Process	338
	Validate the Measurement System for Process Control	341
	Measurement of Process Performance	343
	Six Sigma Process Capability	344
	Non-Normal Distribution Curves	344
	Instability Index	345
	Obtaining Six Sigma process control in "Real Time"	346
	Box-Jenkins and EWMA Charts	347
	Process Adjustments	349
	Defining Process Stability and Repeatability	350
	Real Time Process Stability is Defined	351
	How to Use the Box-Jenkins Bounded Manual Adjustment Chart	351
	Real Time Process Stability	352
	Use of the Box-Jenkins Manual Adjustment Chart	355
	How and When to Adjust the Process	357
	The Bounded Box-Jenkins Manual Adjustment Chart	358
	Computing Standard Error for EWMA	362
	When Should the Process be adjusted?	364
	Potential When an Adjustment is Made	365
	Implement Change with Six Sigma Methodologies	366
	A Better Way to Generate Ideas for Change	371
	Lean Manufacturing Principles	372
	Implement Meetings of Substance	378
	Eight (8)--D Problem Solving Methodology	380
	Organizational Change Experience for Excellence	386
	Tracking Six Sigma Continuous Improvement	387
	Improved Work Flow, Pulled versus Pushed	388
	Communication. Before and After Six Sigma Implementation	389
	Deploying Six Sigma to Customers and Suppliers	389
	References	392
	Glossary	393
Appendix A.	Check Lists for Business and Manufacture	427
Appendix B.	DOE (Design of Experiments)	465
Appendix C.	Six Sigma Quality Control SPC Forms and Data	481
	Index	553

Editorial Reviews

"The book comprises eight chapters supported with 89 figures and 29 tables. The 7-page content lists in detail what is covered in each chapter. The 34-page glossary defines all the terminology used in the book. The book is easy to read and covers concisely the theme of Six Sigma. Some of the chapters contain mathematical formulae that may act as a turn-off for some readers. Yet, this book is very useful not only for readers interested in SS, but for those interested in the field of quality management." —THE TQM MAGAZINE. Vol. 18, No. 4; 2006, K. Narasimhan, Learning and Teaching Fellow, Bolton Institute, UK

From the Publisher