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Full Description
The Practical Guide to Lean Sigma Problem-Solving- Expanded & Updated!Lean Sigma delivers results-if you use the right tools and techniques. In this thoroughly updated edition, Ian Wedgwood details his proven best-practices from more than sixty successful Six Sigma and Lean deployments in multiple industries, helping you identify and apply the solutions that will work best in your projects.This expanded edition of Lean Sigma: A Practitioner's Guide offers detailed guidance on process improvement, standardization, accelerated improvement, and more. Wedgwood helps you identify potential Lean Sigma projects, even in processes without obvious targets. He illuminates fast, effective routes to solving specific business problems, and explains why these solutions work.Next, he presents detailed "tools roadmaps": step-by-step instructions showing exactly how and when to use each of these tools:* 5 Whys* 5S* Affinity* ANOVA* Box plot* Capability* C&E matrix* Chi-Square* Concept ideation, design, selection* Control charts* Control plan summary* Core process map* Critical path analysis* Customer interviewing* Customer requirements tree* Customer surveys* D-Study* Demand profiling* Demand segmentation* DOE* Fishbone diagram* Handoff map* KPOVs & data* Load chart* MSAs* Multi-Cycle analysis* Multi-Vari studies* Murphy's analysis* Normality test* OEE* Pareto chart* Process performance mgmt.* Poka Yoke* Process board* Process FMEA* Process scorecard /dashboard* Process variables (I/O) map* Project charter* Pull systems & Kanban* Rapid changeover (SMED)* Regression* SIPOC* Spaghetti map* Standard work instructions* SPC* Swimlane map* Test of equal variance* Time* Total productive maintenance* T-tests* Value stream mapWith this guide, all Green, Black, or Master Black Belts will benefit from decades of Six Sigma and Lean consulting experience.Register your product at informit.com/register for convenient access to downloads, updates, and corrections as they become available
Contents
Preface xiiiAcknowledgments xviiAbout the Author xixChapter 1: Introduction 1Overview 1Intended Audience 2Prerequisites 2Basics 3How to Use This Book 9And Finally . . . 12Part I: Project Roadmaps to Solve Business Problems 13Chapter 2: Process Improvement Projects (DMAIC) 15Overview 15Define 15Measure and Analyze 24Improve 26Control 33Chapter 3: Standardization Projects (DMASC) 39Overview 39Define 42Measure 45Analyze 46Standardize 47Control 52Chapter 4: Accelerated Improvement Projects (Kaizen) 57Overview 57Pre-Event 59Event 63Post-Event 71Chapter 5: Discovery-Identifying Projects 75Overview 75Tool Approach 77Part II: Routes to Solution 81Chapter 6: Global Process Problems 83A: On-Time Delivery Issues 83B: Capacity of Process Is Too Low 87C: RTY, Defects, Accuracy, Quality, Scrap, and Rework Issues 89D: %Uptime Is Too Low 93E: Pace of Process Is Too Slow 96F: Process Has Enough Capacity but Fails Intermittently 99G: Process Has Enough Capacity, but Process Lead Time Is Too Long 102H: Individual Steps Meet Takt, Global Process Does Not 105I: Demand from the Customer Is Too Variable 108J: Too Many Entity Types (Products) 112K: High Schedule Variation 115L: Measurement System Broken 121M: Performance Characteristic Not Good Enough 124N: Planned Maintenance Takes Too Long 125O: Setup/Changeover Takes Too Long 126P: Too Much Unplanned Maintenance 129Q: Process Can't Make Product at All 134R: Resource Usage Is Too High (Headcount Reduction) 136S: Inventory Is Too High 139T: Waste/Process Loss Is Too High 144U: High Forecast Variation 147V: Not Enough Sales 152W: Backlog of Orders Is Too High 154X: Payments Made to Suppliers Not Optimized 155Y: Accounts Receivable Are Too High 158Chapter 7: Individual Step Process Problems 1631: A Single Process Step Does Not Meet Takt 1632: The Pace for a Single Process Step Is Too Slow 1663: Too Much Variation in the Cycle Time of a Single Step 168Part III: Roadmaps to Guide in the Practical Application of Each Lean Sigma Tool 171Chapter 8: Tools 17301: 5 Whys 17302: 5S 17603: Affinity 18404: ANOVA 18705: Box Plot 19606: Capability-Attribute 19907: Capability-Continuous 20108: Cause and Effect (C&E) Matrix 20909: Chi-Square 21310: Concept Ideation, Design, and Selection 21911: Control Charts 22612: Control Plan Summary 23413: Core Process Map 24214: Critical Path Analysis 24615: Customer Interviewing 24916: Customer Requirements Tree 25817: Customer Surveys 26118: D-Study 26719: Demand Profiling 27220: Demand Segmentation 27721: DOE-Introduction 28322: DOE-Screening 29423: DOE-Characterizing 30324: DOE-Optimizing 31825: Fishbone Diagram 33026: Handoff Map 33427: KPOVs and Data 33828: Load Chart 34929: MSA-Validity 35330: MSA-Attribute 35731: MSA-Continuous 36532: MSA-Process Variation Study (Nested ANOVA) 37533: Multi-Cycle Analysis 38034: Multi-Vari Studies 38635: Murphy's Analysis 39136: Normality Test 39437: Overall Equipment Effectiveness (OEE) 39738: Pareto Chart 40439: Process Performance Management 40740: Poka Yoke (Mistake-Proofing) 41041: Process Board 41442: Process FMEA 41843: Process Scorecard/Dashboard 42344: Process Variables (Input/Output) Map 42945: Project Charter 43246: Pull Systems and Kanban 44147: Rapid Changeover (SMED) 45448: Regression 46149: SIPOC 47150: Spaghetti (Physical Process) Map 47551: Standard Work Instructions 47952: Statistical Process Control (SPC) 48453: Swimlane Map 48854: Test of Equal Variance 49455: Time-Global Process Cycle Time 49756: Time-Individual Step Cycle Time 50057: Time-Process Lead Time 50358: Time-Replenishment Time 50659: Time-Takt Time 50960: Total Productive Maintenance 51461: t-Test-1-Sample 51662: t-Test-2-Sample 52263: t-Test-Paired 52864: Value Stream Map 529Index 541
