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The Practical, Easy-to-Use Guide to Lean Sigma Problem-SolvingLean Sigma delivers results-if you use the right tools and techniques. In Lean Sigma: A Practitioner's Guide, Dr. Ian Wedgwood captures best-practice Lean Sigma experience from multiple projects and industries, helping any professional identify the solution that will work best-and implement it. Wedgwood's exclusive "project roadmaps" present the fastest, most effective route to solving a wide range of problems-and explain why those solutions make sense. His "discovery roadmaps" help you identify potential Lean Sigma projects, even in processes where there are no obvious targets. The heart of Lean Sigma is Wedgwood's 48 individual "tools roadmaps": step-by-step instructions revealing exactly how and when to use all these Lean Sigma tools...* 5 Whys* 5S* Affinity* ANOVA* Boxplots* Capability tools* Cause & effect matrices* Chi-Square* Control charts* Critical path analyses* Customer tools* Demand tools* DOE tools * Fishbone diagrams* Handoff maps* KPOVs * Load charts* MSA tools * Multi-Cycle analyses* Multi-Vari studies* Murphy's analyses* Normality tests* OEE* Pareto charts* Poka Yoke * Process FMEA* Process variables (I/O) maps* Project charter* Pull systems & Kanban* Rapid changeover* Regression* SIPOC* Spaghetti maps* SPC* Swimlane maps* Time toolsWhether you're a Green Belt, Black Belt, Master, Project Champion, Sponsor, Deployment Leader, or consultant, this book will help you use Lean Sigma to solve far more problems, far more rapidly, and far more effectively. Dr. Ian Wedgwood, Executive Director of Sigma Breakthrough Technologies, has more than ten years of experience using, deploying, training, and consulting on Six Sigma and Lean Sigma. He has led and facilitated deployments in industries ranging from electronics and medical devices to chemicals and health care, and has trained and mentored numerous executives, champions, and belts. He holds a Ph.D. and First-Class Honors degree in Applied Mathematics from Scotland's St. Andrew's University.Chapter 1 Introduction 1Chapter 2 Define-Tools Roadmap Applied to the Beginning of All Projects 13Chapter 3 Global Process Problems 23A: On-Time Delivery Issues 23B: Capacity of Process Is Too Low 27C: RTY, Defects, Accuracy, Quality, Scrap, and Rework Issues 29D: % Uptime Is Too Low 33E: Pace of Process Too Slow 36F: Process Has Enough Capacity, But Fails Intermittently 38G: Process Has Enough Capacity, But Process Lead Time Is Too Long 41H: Individual Steps Meet Takt, Global Process Does Not 44I: Demand from the Customer Is Too Variable 47J: Too Many Entity Types (Products) 51K: High Schedule Variation 54L: Measurement System Broken 60M: Performance Characteristic Not Good Enough 63N: Planned Maintenance Takes Too Long 64O: Setup/Changeover Takes Too Long 65P: Too Much Unplanned Maintenance 68Q: Process Can't Make Product at All 72R: Resource Usage Is Too High (Headcount Reduction) 75S: Inventory Is Too High 78T: Waste/Process Loss Too High 82U: High Forecast Variation 85V: Not Enough Sales 89W: Backlog of Orders Is Too High 91X: Payments Made to Suppliers Not Optimized 93Y: Accounts Receivable Are Too High 95Chapter 4 Individual Step Process Problems 99Chapter 5 Control-Tools Used at the End of All Projects 107Chapter 6 Discovery-Tools Applied to Identify Projects 115TOOL Chapter 7 Tools 11901: 5 Whys 11902: 5S 12203: Affinity 13004: ANOVA 13305: Box Plot 14106: Capability-Attribute 14307: Capability-Continuous 14608: Cause & Effect (C&E) Matrix 15309: Chi-Square 15710: Control Charts 16311: Critical Path Analysis 17112: Customer Interviewing 17413: Customer Requirements Tree 18314: Customer Surveys 18615: Demand Profiling 19316: Demand Segmentation 19617: DOE-Introduction 20218: DOE-Screening 21319: DOE-Characterizing 22220: DOE-Optimizing 23721: Fishbone Diagram 24922: Handoff Map 25323: KPOVs and Data 25724: Load Chart 26825: MSA-Validity 27226: MSA-Attribute 27627: MSA-Continuous 28428: Multi-Cycle Analysis 29429: Multi-Vari Studies 30030: Murphy's Analysis 30631: Normality Test 30832: Overall Equipment Effectiveness (OEE) 31133: Pareto Chart 31834: Poka Yoke (Mistake Proofing) 32135: Process FMEA 32536: Process Variables (Input/Output) Map 33037: Project Charter 33338: Pull Systems and Kanban 34239: Rapid Changeover (SMED) 35440: Regression 36241: SIPOC 37242: Spaghetti (Physical Process) Map 37643: Statistical Process Control (SPC) 38044: Swimlane Map 38445: Test of Equal Variance 38946: Time-Global Process Cycle Time 39247: Time-Individual Step Cycle Time 39548: Time-Process Lead Time 39849: Time-Replenishment Time 40150: Time-Takt Time 40451: Total Productive Maintenance 40852: t-Test-1-Sample 41153: t-Test-2-Sample 41654: t-Test-Paired 42255: Value Stream Map 423
Contents
Chapter 1 Introduction 1Chapter 2 Define-Tools Roadmap Applied to the Beginning of All Projects 13Chapter 3 Global Process Problems 23A: On-Time Delivery Issues 23B: Capacity of Process Is Too Low 27C: RTY, Defects, Accuracy, Quality, Scrap, and Rework Issues 29D: % Uptime Is Too Low 33E: Pace of Process Too Slow 36F: Process Has Enough Capacity, But Fails Intermittently 38G: Process Has Enough Capacity, But Process Lead Time Is Too Long 41H: Individual Steps Meet Takt, Global Process Does Not 44I: Demand from the Customer Is Too Variable 47J: Too Many Entity Types (Products) 51K: High Schedule Variation 54L: Measurement System Broken 60M: Performance Characteristic Not Good Enough 63N: Planned Maintenance Takes Too Long 64O: Setup/Changeover Takes Too Long 65P: Too Much Unplanned Maintenance 68Q: Process Can't Make Product at All 72R: Resource Usage Is Too High (Headcount Reduction) 75S: Inventory Is Too High 78T: Waste/Process Loss Too High 82U: High Forecast Variation 85V: Not Enough Sales 89W: Backlog of Orders Is Too High 91X: Payments Made to Suppliers Not Optimized 93Y: Accounts Receivable Are Too High 95Chapter 4 Individual Step Process Problems 99Chapter 5 Control-Tools Used at the End of All Projects 107Chapter 6 Discovery-Tools Applied to Identify Projects 115TOOL Chapter 7 Tools 11901: 5 Whys 11902: 5S 12203: Affinity 13004: ANOVA 13305: Box Plot 14106: Capability-Attribute 14307: Capability-Continuous 14608: Cause & Effect (C&E) Matrix 15309: Chi-Square 15710: Control Charts 16311: Critical Path Analysis 17112: Customer Interviewing 17413: Customer Requirements Tree 18314: Customer Surveys 18615: Demand Profiling 19316: Demand Segmentation 19617: DOE-Introduction 20218: DOE-Screening 21319: DOE-Characterizing 22220: DOE-Optimizing 23721: Fishbone Diagram 24922: Handoff Map 25323: KPOVs and Data 25724: Load Chart 26825: MSA-Validity 27226: MSA-Attribute 27627: MSA-Continuous 28428: Multi-Cycle Analysis 29429: Multi-Vari Studies 30030: Murphy's Analysis 30631: Normality Test 30832: Overall Equipment Effectiveness (OEE) 31133: Pareto Chart 31834: Poka Yoke (Mistake Proofing) 32135: Process FMEA 32536: Process Variables (Input/Output) Map 33037: Project Charter 33338: Pull Systems and Kanban 34239: Rapid Changeover (SMED) 35440: Regression 36241: SIPOC 37242: Spaghetti (Physical Process) Map 37643: Statistical Process Control (SPC) 38044: Swimlane Map 38445: Test of Equal Variance 38946: Time-Global Process Cycle Time 39247: Time-Individual Step Cycle Time 39548: Time-Process Lead Time 39849: Time-Replenishment Time 40150: Time-Takt Time 40451: Total Productive Maintenance 40852: t-Test-1-Sample 41153: t-Test-2-Sample 41654: t-Test-Paired 42255: Value Stream Map 423
