Unlock new levels of quality, performance, customer service, and profits
Written specifically for managers with little or no experience on the subject, Six Sigma for Managers, Second Edition, provides step-by-step guidance and examples for implementing a Six Sigma initiative.
Written specifically for today’s busy manager, Briefcase Books feature eye-catching icons, checklists, and sidebars to guide managers step by step through everyday workplace situations.
- Updated with the latest in implementation strategies and tactics, tips from insiders in the field, and new stories and insights from the Six Sigma experiences of others
- Clear definitions of key management terms and concepts
- Practical advice for minimizing the possibility of error
- Examples of successful management
- Specific planning procedures, tactics, and hands-on techniques
Greg Brue is CEO of Six Sigma Consultants and is a master six sigma black belt.
Foreword, Mikel J. Harry xi
Preface xiii
1. Introduction to Six Sigma 1
What Is Six Sigma? 1
Evolution of the Six Sigma Fundamentals 2
What Is Sigma? 4
Essentials of the Six Sigma Methodology 7
Focus on Engaging People and Changing Processes 9
Not Only Statistics, but Cultural Changes 10
Six Sigma Is
Not . . . 11Manager’s Checklist for Chapter 1 13
2. Defining Quality and Measuring Performance 15
Start with Your Customers 16
Understand Your Processes 19
Determine Your Metrics 21
The Essential Six Sigma Formula 24
Quality and Metrics, First and Last 24
Manager’s Checklist for Chapter 2 25
3. The Right Way to Implement Six Sigma 27
Six Sigma: The Early Years and Implementation Flaws 27
A More Realistic Approach to Six Sigma 29
Readying the Organization 33
Key Players 35
Executive Leaders and Champions 36
Champions 38
Master Black Belts 39
Black Belts 40
Green Belts 41
Communicate! 42
Train! 43
Infrastructure 44
What to Expect from Outside Consultants 45
Getting Started: The Dos 46
Getting Started: The Don’ts 48
Executive Overview of DMAIC 49
Manager’s Checklist for Chapter 3 51
4. Define Phase 53
Define Phase Activities 53
Define the Phase-Gate Review 75
Summary 76
Manager’s Checklist for Chapter 4 76
5. Measure Phase 77
Purposes of the Measure Phase 78
Measure Phase Activities 79
Step 1. Map the Process in Detail 81
Step 2. Create a YX Matrix 84
Step 3. Perform a Failure Modes and Effects Analysis (FMEA) 89
Step 4. Conduct a Measurement System Analysis (MSA) 95
Step 5. Determine Process Capability 104
Z Scores and Sigma Shift 111
Measure Phase-Gate Review 113
Manager’s Checklist for Chapter 5 114
6. Analyze Phase 115
Analyze Phase Activities 116
Analyze Phase Tools 120
Ascertain and Prioritize Vital Few Causes of Variation 142
Transform the Gaps into Improvement Projects 144
Review the Project with the Champion 145
Conduct an Analyze Phase-Gate Review 145
Manager’s Checklist for Chapter 6 146
7. Improve Phase 147
Improve Phase Activities 148
Improve Phase Tools 149
Correlation 149
Regression Analysis 151
Design of Experiments 153
Planning the Experiment (DOE) 155
Conducting the Experiment 165
Running the Experiment 168
Analyzing the Experiment Results 170
Review the Project with the Champion 176
Conduct an Improve Phase-Gate Review 176
Manager’s Checklist for Chapter 7 177
8. Control Phase 179
Control Phase Steps and Tools 180
Control Plan 181
Statistical Process Control 182
Control Charts 196
Contingency Plans for Out-of-Control Conditions 196
Minimizing the Potential for Problems—Mistake Proofing 197
Plan for Transfer to Process Owners 199
Communication Plans 202
Review the Project with the Champion 205
Conduct a Control Phase-Gate Review 206
Control Phase Deliverables 206
Summary 207
Manager’s Checklist for Chapter 8 208
9. How to Sustain Six Sigma 209
Basic Infrastructure Requirements 210
Communication Plan 211
Company Culture 213
Company Cycles 215
Reinforcement and Control 217
Manager’s Checklist for Chapter 9 219
10. Six Sigma Proof Positive 221
Real Final Reports 222
Case Studies 224
Training Agendas 229
Design for Six Sigma 233
The End .. . and the Beginning 235
Manager’s Checklist for Chapter 10 236
Index 239
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