9780071838634

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 . . . 11

Manager’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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Six Sigma for Managers, Second Edition (Briefcase Books Series)

Six Sigma for Managers, Second Edition (Briefcase Books Series)

0071838635

Summary

Table of Contents

Supplemental Materials