Six sigma for the new millennium

457 Pages·2009·4.075 MB·English

by  Pries, Kim H

Six Sigma for the
New Millennium
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Six Sigma for the
New Millennium
A CSSBB Guidebook
Kim H. Pries
ASQ Quality Press
Milwaukee, Wisconsin
American Society for Quality, Quality Press, Milwaukee 53203
© 2009 by ASQ
All rights reserved. Published 2009
Printed in the United States of America
15 14 13 12 11 10 09 5 4 3 2 1
Library of Congress Cataloging-in-Publication Data
Pries, Kim H., 1955-
Six sigma for the new millennium / Kim H. Pries. -- 2nd ed.
p. cm.
ISBN 978-0-87389-749-5 (soft cover)
1. Six sigma (Quality control standard) 2. Total quality management. 3. Quality control.
I. Title.
HD62.15.P75 2009
658.4’013--dc22
2008042585
No part of this book may be reproduced in any form or by any means, electronic,
mechanical, photocopying, recording, or otherwise, without the prior written permission
of the publisher.
Publisher: William A. Tony
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Six Sigma for the New Millennium
Contents
List of Tables ..............................................................................................................................vii
List of Figures ...........................................................................................................................viii
Preface ..........................................................................................................................................xi
Section 1 Enterprise-Wide Deployment .................................................................................1
Enterprise-Wide View ........................................................................................................3
Leadership ..........................................................................................................................41
Section 2 Organizational Process Management and Measures .......................................53
Organizational Process Management ...........................................................................55
Organizational Process Measures ..................................................................................63
Section 3 Team Management ..................................................................................................71
Team Formation .................................................................................................................73
Team Facilitation ...............................................................................................................83
Team Dynamics .................................................................................................................91
Time Management for Teams .........................................................................................99
Team Decision-Making Tools .......................................................................................111
Management and Planning Tools ................................................................................117
Team Performance Evaluation and Reward ...............................................................133
Section 4 Define .......................................................................................................................143
Voice of the Customer ....................................................................................................145
Project Charter .................................................................................................................157
Project Tracking ...............................................................................................................171
Section 5 Measure ...................................................................................................................181
Process Characteristics ...................................................................................................183
Data Collection ................................................................................................................191
Measurement Systems ...................................................................................................201
Basic Statistics ..................................................................................................................213
Probability ........................................................................................................................225
Process Capability ...........................................................................................................237
Section 6 Analyze ....................................................................................................................253
Measuring and Modeling Relationships Between Variables .................................255
v
Contents
Hypothesis Testing .........................................................................................................269
Failure Mode and Effects Analysis (FMEA) ..............................................................295
Additional Analysis Methods ......................................................................................313
Section 7 Improve ...................................................................................................................321
Design of Experiments (DOE) ......................................................................................323
Lean Practices ...................................................................................................................337
Beyond Lean .....................................................................................................................345
Statistical Process Control .............................................................................................353
Section 8 Control .....................................................................................................................371
Other Control Tools ........................................................................................................373
Maintain Controls ...........................................................................................................379
Sustain Improvements ...................................................................................................385
Section 9 Design for Six Sigma Framework and Methodologies .................................395
Common DFSS Methodologies ....................................................................................397
DFSS Design Tools .........................................................................................................403
Glossary ....................................................................................................................................413
Appendix A Table of Control Chart Parameters ...............................................................415
Appendix B Chi-Square Values ............................................................................................416
Appendix C F-Test Values .....................................................................................................417
Appendix D Standard Normal Values ................................................................................419
Appendix E T-Test Values (One-Sided) ..............................................................................420
Appendix F Binomial Distribution .....................................................................................421
Appendix G Cumulative Poisson Distribution ................................................................433
Index ...........................................................................................................................................437
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Six Sigma for the New Millennium
List of Tables
Table 3.1 Groupthink ................................................................................................................95
Table 3.2 The “L” diagram. ....................................................................................................125
Table 3.3 The ‘T’ diagram. ......................................................................................................125
Table 3.4 The “X” diagram. ....................................................................................................125
Table 5.1 Different measurement scales. ............................................................................195
Table 5.2 A simple check sheet. ............................................................................................199
Table 5.3 Example of coded control chart data. .................................................................199
Table 5.2 The interrelationships among Cp, Cpk, Sigma limits, and PPM. ................246
Table 6.1 Goodness-of-fit example . .....................................................................................279
Table 6.2 Data table for a two-way ANOVA from Minitab example. ...........................283
Table 6.3 2 x 2 contingency table example ..........................................................................285
Table 6.4 2 x 3 contingency table example. .........................................................................285
Table 6.5 List of non-parametric tests. .................................................................................287
Table 6.6 FMEA occurrence values. .....................................................................................303
Table 6.7 FMEA severity criteria. .........................................................................................303
Table 6.8 The header information for an FMEA table showing the position
of the RPN. ...............................................................................................................................307
Table 6.9 The seven wastes can also cause ecological/environmental problems. .......319
Table 6.10 Examples of waste. ...............................................................................................319
Table 7.1 Full-factorial, 2-level, 3-factor. .............................................................................325
Table 7.2 Fractional factorial (one example), 2-level, 3-factor. ........................................325
Table 7.3 Full-factorial, 2-level, 3-factor with interactions: .............................................325
Table 7.4 Plackett-Burman Design for 7 factors. ...............................................................327
Table 7.5 Taguchi Design for 7 factors. ...............................................................................327
Table 7.6 A fractional design for 7 factors. .........................................................................327
Table 7.7 Latin square. ............................................................................................................331
Table 7.8 Differences between variables and attributes-based control charts. ...........357
Table 9.1 The TRIZ 40 Principles. ........................................................................................411
vii
List of Figures
List of Figures
Figure 1.1 Simple organization chart for an enterprise. ....................................................35
Figure 1.2 A very high-level view of a business process ...................................................37
Figure 1.3 The sequence of steps in a SIPOC diagram ......................................................37
Figure 1.4 The Creveling, et al. approach to Six Sigma for marketing. ..........................39
Figure 1.5 Organizational Constructs ....................................................................................47
Figure 2.1 Stakeholder relationship ......................................................................................57
Figure 2.2 Andersen and Pettersen’s model for benchmarking .......................................61
Figure 2.3 The standard Six Sigma formulas. ......................................................................65
Figure 2.4 Return on investment ............................................................................................67
Figure 2.5 Example quality loss function .............................................................................69
Figure 3.1 One model for Six Sigma roles ............................................................................77
Figure 3.2. Team Resource Matrix ..........................................................................................79
Figure 3.3 The ’Orming model................................................................................................87
Figure 3.5 Force field analysis for buying a new house ...................................................115
Figure 3.6 An affinity diagram for a laboratory. ................................................................119
Figure 3.8 An example of a PDPC used for roof leaks. ....................................................123
Figure 3.9 Interrelationship digraph of a test equipment problem. .............................127
Figure 3.10 Prioritization matrix example ..........................................................................129
Figure 3.11 An activity network diagram for a laboratory test. ......................................131
Figure 4.1. Radar graph showing qualitative information on ordinal scales. .............153
Figure 4.2 Simple critical-to-quality tree ............................................................................155
Figure 4.3 Spreadsheet form of Gantt chart. ......................................................................161
Figure 4.4 An example of scheduling under various headings for a Texas
school district. ..........................................................................................................................173
Figure 4.5 Gantt chart example also showing hierarchy of work breakdown
structure elements. ..................................................................................................................175
Figure 4.6 A waterfall representation of a tollgate sequence. ........................................177
Figure 5.3 Process analysis flow chart. ................................................................................189
Figure 5.4 Two representations of data types, dollars being discrete and flow
being continuous. ....................................................................................................................193
viii
Six Sigma for the New Millennium
Figure 5.5 Dial caliper (above) and micrometer (below). Author photo. .....................203
Figure 5.6 Mitutoyo optical comparator (center). Author photo. ...................................203
Figure 5.8 Instron pull tester used for destructive testing. Author photo. ..................207
Figure 5.9 Unholtz-Dickie vibration table for destructive testing. Author photo. .....207
Figure 5.10 Sources of variation in a measurement system. ...........................................211
Figure 5.11 Basic statistical definitions. ..............................................................................215
Figure 5.12 Basic descriptions of dispersion. .....................................................................217
Figure 5.13 Four-way testing for a probability distribution function...........................219
Figure 5.14 Four types of data plots (histogram, scatterplot, boxplot, and
run plot). ...................................................................................................................................221
Figure 5.15 A Weibull analysis of ‘no trouble found’ data ..............................................223
Figure 5.16 Probability notation and rules. ........................................................................227
Figure 5.17 Venn diagrams representing probability logic. ............................................227
Figure 5.18 The appearance of the Binomial and Poisson distributions ......................229
Figure 5.19 The Normal Distribution compared to the Chi-Squared Distribution. ..231
Figure 5.20 Multiple portraits of the F Distribution. .......................................................233
Figure 5.21 The Lognormal Distribution compared to the Exponential
Distribution. .............................................................................................................................235
Figure 5.22 The Lognormal Distribution compared with the Weibull
Distribution. .............................................................................................................................235
Figure 5.23 Calculating Cp and Cpk and Pp and Ppk ......................................................239
Figure 5.24 Capacitor study. Product is potentially capable, but not very close
to center. ....................................................................................................................................241
Figure 5.25 Some typical industrial values for Cpk. ........................................................243
Figure 5.26 The Box-Cox transform to normal representation. ......................................245
Figure 5.27 A log-normal capability study using Minitab. .............................................245
Figure 5.28 Attribute capability study of sales failures. ..................................................247
Figure 5.29 Capability study of a scheduling analysis. ...................................................251
Figure 5.30 Capability study of a capacitor at -40˚C. ........................................................251
Figure 6.1 Linear regression, including the correlation coefficient and residuals. ....257
Figure 6.2 Linear regression results using Minitab and confidence values. ................259
ix