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Bibliographic Details
Main Authors:	Morgan, John (Author), Brenig-Jones, Martin (Author)
Format:	Book
Language:	English
Published:	Chichester [u.a.] Wiley 2012
Edition:	2. ed.
Series:	... for dummies
Subjects:	Lean Management Six Sigma
Links:	http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=024890934&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA
Physical Description:	XVI, 300 S. Ill., graph. Darst.
ISBN:	9781119953708

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adam_text	Titel: Lean six sigma for dummies Autor: Morgan, John Jahr: 2012 Table of Contents Introduction................................................................. 7 About This Book..............................................................................................1 Conventions Used in This Book.....................................................................2 Foolish Assumptions.......................................................................................2 How This Book Is Organised..........................................................................3 Part I: Lean Six Sigma Basics................................................................3 Part H: Working with Lean Six Sigma...................................................3 Part III: Assessing Performance...........................................................4 Part IV: Improving the Processes........................................................4 Part V: Deploying Lean Six Sigma........................................................5 Part VI: The Part of Tens.......................................................................5 Icons Used In This Book.................................................................................5 Where to Go From Here..................................................................................6 Part 1: Lean Sw Sigma Basics........................................ 7 Chapter 1: Defining Lean Six Sigma..............................9 Introducing Lean Thinking.............................................................................9 Bringing on the basics of Lean...........................................................10 Perusing the principles of Lean thinking..........................................15 Sussing Six Sigma...........................................................................................15 Considering the core of Six Sigma.....................................................16 Calculating process sigma values......................................................19 Meeting the major points of Six Sigma..............................................22 Chapter 2: Understanding the Principles of Lean Six Sigma........23 Considering the Key Principles of Lean Six Sigma....................................23 Improving Existing Processes: Introducing DMAIC...................................25 Defining your project...........................................................................26 Measuring how the work is done.......................................................32 Analysing your process.......................................................................32 Improving your process......................................................................33 Coming up with a control plan...........................................................33 Reviewing Your DMAIC Phases....................................................................34 Taking a Pragmatic Approach......................................................................37 Part 11: Working with Lean Six Sigma.......................... 41 Chapter 3: Identifying Your Customers...........................43 Understanding the Process Basics..............................................................43 Pinpointing the elements of a process..............................................44 Identifying internal and external customers....................................45 Getting a High-Level Picture.........................................................................47 Drawing a high-level process map.....................................................48 Segmenting customers........................................................................51 Chapter 4: Understanding Your Customers Needs................53 Can You Kano?...............................................................................................53 Obtaining the Voice of the Customer..........................................................55 Taking an outside-in view...................................................................55 Segmenting your customers...............................................................56 Prioritising your customers................................................................57 Researching the Requirements....................................................................57 Interviewing your customers.............................................................60 Focusing on focus groups...................................................................61 Considering customer surveys..........................................................62 Using observations..............................................................................63 Avoiding Bias.................................................................................................64 Considering Critical To Quality Customer Requirements........................65 Establishing the Real CTQs..........................................................................69 Prioritising the requirements.............................................................70 Measuring performance using customer-focused measures.........71 Chapter 5: Determining the Chain of Events......................73 Finding Out How the Work Gets Done........................................................73 Practising process stapling................................................................74 Drawing spaghetti diagrams...............................................................76 Painting a Picture of the Process.................................................................77 Keeping things simple.........................................................................79 Developing a deployment flowchart..................................................80 Seeing the value in a value stream map............................................84 Identifying moments of truth.............................................................93 Part HI: Assessing Performance...................................95 Chapter 6: Gathering Information...............................97 Managing by Fact...................................... 97 Realising the importance of good data.............................................98 Reviewing what you currently measure..........................................98 Deciding what to measure............... .............99 Developing a Data Collection Plan............................................................100 Beginning with output measures.....................................................100 Creating clear definitions..................................................................102 Agreeing rules to ensure valid and consistent data......................102 Collecting the data.............................................................................105 Identifying ways to improve your approach..................................107 An Introduction to Sampling......................................................................108 Process sampling...............................................................................109 Population sampling..........................................................................Ill Chapter 7: Presenting Your Data...............................117 Delving into Different Types of Variation.................................................117 Understanding natural variation......................................................118 Spotlighting special cause variation................................................118 Distinguishing between variation types..........................................119 Avoiding tampering...........................................................................119 Displaying data differently................................................................120 Recognising the Importance of Control Charts.......................................121 Creating a control chart....................................................................122 Unearthing unusual features............................................................123 Choosing the right control chart.....................................................126 Examining the state of your processes...........................................127 Considering the capability of your processes...............................129 Additional ways to present and analyse your data.......................133 Testing Your Theories................................................................................135 Chapter 8: Analysing What s Affecting Performance.............139 Unearthing the Usual Suspects..................................................................139 Generating your list of suspects......................................................140 Investigating the suspects and getting the facts...........................142 Getting a Balance of Measures...................................................................143 Connecting things up........................................................................143 Proving your point.............................................................................145 Seeing the point.................................................................................146 Assessing your effectiveness............................................................148 Part IV: Improving the Processes............................... 153 Chapter 9: Identifying Value-Added Steps and Waste............155 Interpreting Value-Added...........................................................................155 Providing a common definition........................................................156 Carrying out a value-added analysis...............................................157 Assessing opportunity......................................................................160 Looking at the Seven Wastes.....................................................................160 Owning up to overproduction..........................................................161 Playing the waiting game..................................................................162 Troubling over transportation.........................................................162 Picking on processing.......................................................................162 Investigating inventory.....................................................................163 Moving on motion..............................................................................163 Coping with correction.....................................................................165 Looking Beyond the Seven Wastes............................................................165 Wasting people s potential...............................................................165 Going green.........................................................................................166 Considering customer perspectives................................................166 Focusing on the Vital Few...........................................................................167 Chapter 10: Discovering the Opportunity for Prevention..........169 Keeping Things Neat and Tidy...................................................................170 Introducing the Five Ss......................................................................170 Carrying out a red-tag exercise........................................................171 Using visual management.................................................................172 Looking at Prevention Tools and Techniques.........................................175 Introducing Jidoka.............................................................................175 Reducing risk with Failure Mode Effects Analysis (FMEA)...........176 Error proofing your processes.........................................................179 Profiting from Preventive Maintenance....................................................181 Avoiding Peaks and Troughs.....................................................................182 Introducing Heijunka.........................................................................182 Spreading the load.............................................................................183 Carrying out work in a standard way..............................................184 Chapter 11: Identifying and Tackling Bottlenecks................185 Applying the Theory of Constraints..........................................................185 Identifying the weakest link..............................................................185 Improving the process flow..............................................................186 Building a buffer.................................................................................188 Managing the Production Cycle.................................................................189 Using pull rather than push production.........................................189 Moving to single piece flow..............................................................190 Recognising the problem with batches..........................................191 Looking at Your Layout..............................................................................191 Identifying wasted movement..........................................................191 Using cell manufacturing techniques..............................................191 Identifying product families.............................................................193 Chapter 12: Introducing Design for Six Sigma...................195 Introducing DfSS..........................................................................................196 Introducing DMADV..........................................................................196 Defining What Needs Designing.................................................................197 Getting the measure of the design...................................................198 Analysing the design.........................................................................198 Developing the design.......................................................................200 Verifying that the design works.......................................................200 Choosing between DMAIC and DMADV..........................................201 Considering Quality Function Deployment..............................................202 What are these houses and rooms all about?................................203 Undertaking a QFD drill-down.........................................................212 Decisions, Decisions....................................................................................213 Part V: Deploying Lean Six Sigma..............................217 Chapter 13: Leading the Deployment...........................219 Key Factors for Successful Deployment ..................................................220 Executive Sponsorship...............................................................................220 A Few Words about Size.............................................................................222 The Deployment Programme Manager....................................................223 Lean Six Sigma Start Up..............................................................................225 Project Champions......................................................................................226 Chapter 14: Selecting the Right Projects........................229 Generating a List of Candidate Improvement Projects...........................229 Working Out if Lean Six Sigma Is the Right Approach............................232 Prioritising projects...........................................................................233 Using a Criteria Selection Matrix.....................................................234 Deciding on which approach fits which project: Doing the work right.....................................................................236 Setting up a DMAIC Project........................................................................237 Seeing Rapid Improvement with a Kai Sigma Event................................238 Chapter 15: Understanding the People Issues...................241 Working Right Right from the Start.........................................................241 Gaining Acceptance.....................................................................................242 Managing change...............................................................................242 Overcoming resistance.....................................................................244 Creating a Vision..........................................................................................245 Understanding Organisational Culture.....................................................247 Busting Assumptions..................................................................................248 Seeing how People Cope with Change......................................................249 Comparing energy and attitude.......................................................250 Using a forcefield diagram................................................................251 Analysing your stakeholders............................................................251 Focusing on key elements of change...............................................253 Chapter 16: Ten Best Practices................................257 Lead and Manage the Programme.............................................................257 Appreciate that Less Is More.....................................................................258 Build in Prevention......................................................................................259 Challenge Your Processes..........................................................................260 GototheGemba..........................................................................................261 Manage Your Processes with Lean Six Sigma..........................................261 Pick the Right Tools for the Job................................................................262 Tell the Whole Story....................................................................................263 Understand the Role of the Champion.....................................................264 Looking at the Lean Six Sigma programme business champion.........................................................................................264 Perusing the role of the project champion.....................................264 Use Strategy to Drive Lean Six Sigma........................................................265 Chapter 17: Ten Pitfalls to Avoid...............................267 Jumping to Solutions...................................................................................267 Coming Down with Analysis Paralysis......................................................268 Falling into Common Project Traps..........................................................269 Methodology madness......................................................................269 Scope scandals...................................................................................269 Team turmoil......................................................................................270 Lack of support..................................................................................270 Stifling the Programme Before You ve Started........................................270 Ignoring the Soft Stuff..................................................................................271 Getting Complacent.....................................................................................271 Thinking We re Already Doing It ..............................................................272 Believing the Myths.....................................................................................272 Doing the Wrong Things Right...................................................................273 Overtraining.................................................................................................274 Chapter 18: Ten Places to Go for Help..........................275 Your Colleagues...........................................................................................275 Your Champion............................................................................................276 Other Organisations............................. .................................276 The Internet.................................................. ..............................................276 Networks and Associations................................................................278 Conferences..................................................................................................278 Books.............................................................................................................278 Periodicals....................................................................................................279 Software........................................................................................................280 Statistical analysis.............................................................................280 Deployment management.................................................................281 Training and Consultancy Companies......................................................281 Index.......................................................................283
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series2	... for dummies
spellingShingle	Morgan, John Brenig-Jones, Martin Lean Six Sigma for dummies [Learn to: enhance business efficiency and reduce waste ; successfully deploy Lean Six Sigma projects in your organisation ; manage projects more tightly and fine-tune existing systems ; apply Lean Six Sigma thinking to your day-to-day activities] Lean Management (DE-588)4300840-9 gnd Six Sigma (DE-588)7604241-8 gnd
subject_GND	(DE-588)4300840-9 (DE-588)7604241-8
title	Lean Six Sigma for dummies [Learn to: enhance business efficiency and reduce waste ; successfully deploy Lean Six Sigma projects in your organisation ; manage projects more tightly and fine-tune existing systems ; apply Lean Six Sigma thinking to your day-to-day activities]
title_auth	Lean Six Sigma for dummies [Learn to: enhance business efficiency and reduce waste ; successfully deploy Lean Six Sigma projects in your organisation ; manage projects more tightly and fine-tune existing systems ; apply Lean Six Sigma thinking to your day-to-day activities]
title_exact_search	Lean Six Sigma for dummies [Learn to: enhance business efficiency and reduce waste ; successfully deploy Lean Six Sigma projects in your organisation ; manage projects more tightly and fine-tune existing systems ; apply Lean Six Sigma thinking to your day-to-day activities]
title_full	Lean Six Sigma for dummies [Learn to: enhance business efficiency and reduce waste ; successfully deploy Lean Six Sigma projects in your organisation ; manage projects more tightly and fine-tune existing systems ; apply Lean Six Sigma thinking to your day-to-day activities] by John Morgan and Martin Brenig-Jones
title_fullStr	Lean Six Sigma for dummies [Learn to: enhance business efficiency and reduce waste ; successfully deploy Lean Six Sigma projects in your organisation ; manage projects more tightly and fine-tune existing systems ; apply Lean Six Sigma thinking to your day-to-day activities] by John Morgan and Martin Brenig-Jones
title_full_unstemmed	Lean Six Sigma for dummies [Learn to: enhance business efficiency and reduce waste ; successfully deploy Lean Six Sigma projects in your organisation ; manage projects more tightly and fine-tune existing systems ; apply Lean Six Sigma thinking to your day-to-day activities] by John Morgan and Martin Brenig-Jones
title_short	Lean Six Sigma for dummies
title_sort	lean six sigma for dummies learn to enhance business efficiency and reduce waste successfully deploy lean six sigma projects in your organisation manage projects more tightly and fine tune existing systems apply lean six sigma thinking to your day to day activities
title_sub	[Learn to: enhance business efficiency and reduce waste ; successfully deploy Lean Six Sigma projects in your organisation ; manage projects more tightly and fine-tune existing systems ; apply Lean Six Sigma thinking to your day-to-day activities]
topic	Lean Management (DE-588)4300840-9 gnd Six Sigma (DE-588)7604241-8 gnd
topic_facet	Lean Management Six Sigma
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