Fit Sigma: A Lean Approach to Building Sustainable Quality Beyond Six Sigma

257 Pages·2011·2.7 MB·English

by  Ron Basu

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FIT SIGMA
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ForothertitlesintheWileyFinanceseries
pleaseseewww.wiley.com/finance
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FIT SIGMA
A Lean Approach to Building Sustainable
Quality Beyond Six Sigma
Ron Basu
A John Wiley and Sons, Ltd., Publication
iii
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Thiseditionfirstpublished2011
©2011RonBasu
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LibraryofCongressCataloging-in-PublicationData
Basu,Ron.
FitSigma:aleanapproachtobuildingsustainablequalitybeyondSixSigma/RonBasu.
p.cm.
ISBN978-0-470-66621-0
1.Manufacturingprocesses–QualityControl. 2.IndustrialManagement–QualityControl. 3.SixSigma
(QualityControlStandard) I.Title.
TS156.B43262011
658.4(cid:1)013–dc22
AcataloguerecordforthisbookisavailablefromtheBritishLibrary.
ISBN978-0-470-66621-0(hardback);ISBN978-1-119-99112-0(ebk);
ISBN978-1-119-97372-0(epub);ISBN978-1-119-97373-7(emobi)
Typesetin10/12ptTimesbyAptaraInc.,NewDelhi,India
PrintedandboundinGreatBritainbyCPIAntonyRowe,Chippenham,Wiltshire
iv
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ToMoira,BonnieandRobi
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vi
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Contents
Preface xi
Acknowledgements xv
AbouttheAuthor xvii
1 TheEvolutionofSixSigma,LeanSigmaandFITSIGMATM 1
1.1 Introduction 1
1.2 FirstWave:AsIstoTQM 3
1.3 SecondWave:TQMtoLeanSigma 3
1.4 ThirdWave:LeanSigmatoFITSIGMA 4
1.5 MoreaboutSixSigma 5
1.6 WhatisSixSigma? 6
1.7 TheStructuredApproachofSixSigma 8
1.8 WhatisLeanSigma? 10
1.9 MoreonLeanSigma 13
1.10 WhyFITSIGMA? 13
1.11 Summary 14
2 MoreaboutFITSIGMA 15
2.1 Introduction 15
2.2 FitnessforthePurpose 17
2.3 Sigma((cid:1))forImprovementandIntegration 19
2.4 FitnessforSustainability 28
2.5 Summary 41
3 DMAICMethodologyforFITSIGMA 43
3.1 Introduction 43
3.2 DMAICFull 44
3.3 DMAICLite 50
3.4 KaizenEvent 52
3.5 Summary 54
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viii Contents
4 FITSIGMATools 57
4.1 Introduction 57
4.2 Toolsfor‘Define’ 57
4.3 Toolsfor‘Measure’ 66
4.4 Toolsfor‘Analyse’ 77
4.5 Toolsfor‘Improve’ 87
4.6 Toolsfor‘Control’ 98
4.7 Summary 105
5 FITSIGMAinLargeManufacturingOperations 107
5.1 Introduction 107
5.2 FitnessforthePurpose 107
5.3 Sigma((cid:1))forImprovementandIntegration 108
5.4 FitnessforSustainability 116
5.5 FITSIGMAinSupplyChainManagement 116
5.6 Summary 118
6 FITSIGMAinServiceOperations 119
6.1 Introduction 119
6.2 TheDivideBetweenServiceandManufacturing 120
6.3 ObjectivesofaServiceOrganisation 121
6.4 ‘FitnessforthePurpose’forServiceOrganisations 123
6.5 ‘Sigma((cid:1))forImprovement’forServiceOrganisations 124
6.6 FitnessforSustainability 126
6.7 Summary 128
7 FITSIGMAinSmallandMediumEnterprises 129
7.1 Introduction 129
7.2 ‘FitnessforthePurpose’forSmallandMediumEnterprises 131
7.3 ‘Sigma((cid:1))forImprovement’forSmallandMediumEnterprises 132
7.4 FitnessforSustainability 135
7.5 Summary 136
8 FITSIGMAinProjectManagement 137
8.1 Introduction 137
8.2 FITSIGMAPrinciplesinAddressingProjectManagementObjectives 139
8.3 FITSIGMAinaMajorProject(HighSpeed1) 145
8.4 Summary 148
9 FITSIGMAinGreenThinking 149
9.1 Introduction 149
9.2 WhatisGreenThinking? 150
9.3 WhyFITSIGMAisRelevanttoGreenThinking 151
9.4 TheRolesofStakeholders 152
9.5 HowFITSIGMACanHelpGreenThinking 156
9.6 GreenSigma 159
9.7 Summary 160