Handbook on Continuous Improvement Transformation: The Lean Six Sigma Framework and Systematic Methodology for Implementation

652 Pages·2013·6.87 MB·English

by  Aristide van Aartsengel

Aristide van Aartsengel
Selahattin Kurtoglu
Handbook
on Continuous
Improvement
Transformation
The Lean Six Sigma Framework
and Systematic Methodology
for Implementation
Handbook on Continuous Improvement
Transformation
.
Aristide van Aartsengel (cid:129) Selahattin Kurtoglu
Handbook
on Continuous
Improvement
Transformation
The Lean Six Sigma Framework
and Systematic Methodology
for Implementation
AristidevanAartsengel SelahattinKurtoglu
WijkAanZee Bochum
Netherlands Germany
ISBN978-3-642-35900-2 ISBN978-3-642-35901-9(eBook)
DOI10.1007/978-3-642-35901-9
SpringerHeidelbergNewYorkDordrechtLondon
LibraryofCongressControlNumber:2013933989
#Springer-VerlagBerlinHeidelberg2013
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Acknowledgments
Throughout the two books entitled: “A Guide to Continuous Improvement Trans-
formation: Concepts, Processes, Implementation” and “Handbook on Continuous
Improvement Transformation: The Lean Six Sigma Framework and Systematic
Methodology for Implementation,” we have referenced many illustrious
practitioners to whom we are obviously indebted. The text of these volumes
books has also been hugely improved through the friendly criticism and advice
givenbyvariousextremelygenerousindividuals.
Wewouldliketoexpressourgratitudetoallthosewhotaughtus,whoworked
withusovertheyears,andwhohavehelpeduswiththisworkorinspirednewideas.
Theyare,literally,toonumeroustomention.Manyoftheideasandexamplescome
from practice. We are therefore especially indebted to the many colleagues,
managers, and CEOs who have allowed us to share their work on continuous
improvementandprojectmanagement.
We also wish to acknowledge dozens of people from our client organizations,
practicingKaizeninmanufacturingplants,BusinessProcessManagement,Project
Management, Lean Six Sigma, Lean Manufacturing, Total Quality Management
(TQM),TotalQualityControl(TQC),andTotalProductiveMaintenance(TPM),to
whomweowespecialthanksandwhohaveshowntheapplicabilityoftheideasand
methodsdescribedinthishandbook.
We would also like to acknowledge all the client organizations over the years
thathavetrustedouradviceandprovideduswiththegreatestlaboratorythereis—
theirorganizations.Theirwillingnesstotestnewhypothesescontributedgreatlyto
the material. We extend a deep bow to IQPM Consulting for giving us such an
interestingsubjectaboutwhichtolearn.
Finally,ourfamiliesdeservelovingmention,andsincerethanks,forputtingup
withthehoursoftimespenthunchedoverourcomputerswritingandrevisingthe
contentofthisbook.
WijkAanZee,Netherlands AristidevanAartsengelPh.D.,
Bochum,Germany SelahattinKurtogluPh.D.,
v
.
Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 ThePurposeofThisBook . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 WhatMakesThisBookDifferent . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 HowIsThisBookStructured? . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 DefiningLeanSixSigma . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 SettingtheStage:WhySixofTheseSigma? . . . . . . . . . . . . . . . 7
2.2 StandardDeviation,QualityandCost . . . . . . . . . . . . . . . . . . . . 11
2.3 QualityRelatedCostsElements . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3.1 PreventionCosts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.3.2 AppraisalCosts .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. 13
2.3.3 FailureCosts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.3.4 TheCostofQuality . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.4 WhyLean? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.4.1 EarlyProductionDevelopments . . . . . . . . . . . . . . . . . . . 18
2.4.2 ScientificManagementandMassProduction
Developments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.4.3 PrinciplesofMassProduction . . . . . . . . . . . . . . . . . . . . 20
2.4.4 “Lean”or“Flexible”ProductionMethod . . . . . . . . . . . . 22
2.5 Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3 FrameworkandMethodology . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.1 OperationalDefinitionofaProcess . . . . . . . . . . . . . . . . . . . . . . 25
3.2 SettingtheFrameworkandMethodology . . . . . . . . . . . . . . . . . 27
4 “PDSAInitiate”ProcessGroup . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.1 IdentifyCustomersandStakeholders . . . . . . . . . . . . . . . . . . . . 33
4.1.1 DevelopaListofCustomersandStakeholders . . . . . . . . 34
4.1.2 AnalyzeStakeholdersandTheirInterests . . . . . . . . . . . . 39
4.1.3 RecordStakeholdersInformation . . . . . . . . . . . . . . . . . . 42
4.2 DevelopProjectCharter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.2.1 ProjectPurposeorJustification . . . . . . . . . . . . . . . . . . . 43
4.2.2 ProjectSuccessCriteria . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.2.3 High-LevelDescriptionofthe“ProcesstobeImproved” . . . 44
4.2.4 Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
vii
viii Contents
4.3 DevelopPreliminaryProjectScopeStatement . . . . . . . . . . . . . . 49
4.3.1 DefiningtheProjectObjectives . . . . . . . . . . . . . . . . . . . 50
4.4 PerformPhaseReview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5 “PDSAPlan”ProcessGroup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.1 ThePurposeofPlanning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.2 The“PDSAPlan”ConstituentProcesses . . . . . . . . . . . . . . . . . . 54
6 DevelopProjectManagementPlan . . . . . . . . . . . . . . . . . . . . . . . . 57
6.1 Elementsofa“ProcessImprovement”ProjectPlan . . . . . . . . . . 58
6.1.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6.1.2 Phases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.1.3 Milestones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.1.4 Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
6.1.5 Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
6.1.6 Effort . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
6.1.7 Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6.1.8 ProjectSchedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6.1.9 ProjectRisk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6.2 CollatingtheMaterials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
7 DevelopProjectManagementScope . . . . . . . . . . . . . . . . . . . . . . . 65
7.1 CollectRequirements:V.O.B.,V.O.C.,&V.O.P. . . . . . . . . . . . 67
7.2 DefineScope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
7.3 VerifyScope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
7.4 ControlScope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
7.4.1 ScopeCreep . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
7.4.2 HopeCreep . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
7.4.3 EffortCreep . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
7.4.4 FeatureCreep . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
8 CollectingV.O.C.Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 75
8.1 PlanV.O.C.Capturing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
8.1.1 IdentifyV.O.C.DataandClarifyGoals . . . . . . . . . . . . . 77
8.1.2 DevelopOperationalDefinitionsandProcedures . . . . . . 77
8.1.3 DevelopSamplingStrategy . . . . . . . . . . . . . . . . . . . . . . 89
8.1.4 ValidateDataCollectionSystem . . . . . . . . . . . . . . . . . . 92
8.2 CollectandOrganizeData . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
8.2.1 OrganizeV.O.C.Data:AffinityClustering . . . . . . . . . . . 125
8.3 AnalyzeDataandGenerateCustomerKeyNeeds . . . . . . . . . . . 128
8.4 TranslateCustomerKeyNeedsintoCTXs . . . . . . . . . . . . . . . . 130
8.5 SetSpecificationsforCTXs . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
8.6 Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Contents ix
9 CreateWorkBreakdownStructure . . . . . . . . . . . . . . . . . . . . . . . . 137
9.1 DefiningaWorkBreakdownStructure . . . . . . . . . . . . . . . . . . . 137
9.2 DevelopingaWorkBreakdownStructure . . . . . . . . . . . . . . . . . 138
9.3 UsesofaWorkBreakdownStructure . . . . . . . . . . . . . . . . . . . . 141
10 DevelopTimeManagementPlan . . . . . . . . . . . . . . . . . . . . . . . . . . 143
10.1 DefineActivities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
10.2 AssessCompletenessofActivities . . . . . . . . . . . . . . . . . . . . . 145
10.3 SequenceActivities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
10.3.1 NetworkDiagramFormalism . . . . . . . . . . . . . . . . . . . 147
10.3.2 NetworkPreparation . . . . . . . . . . . . . . . . . . . . . . . . . 149
10.3.3 ConstructingtheProjectNetworkDiagram . . . . . . . . . 150
10.4 EstimateActivityResources . . . . . . . . . . . . . . . . . . . . . . . . . . 151
10.5 EstimateActivityDurations . . . . . . . . . . . . . . . . . . . . . . . . . . 151
11 DevelopProjectSchedulePlan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
11.1 BasicApproachtoScheduling . . . . . . . . . . . . . . . . . . . . . . . . 156
11.2 UpdatetheProjectNetworkDiagram . . . . . . . . . . . . . . . . . . . 156
11.2.1 ShowingTimesonArrowNetworks . . . . . . . . . . . . . . 157
11.2.2 TheProgramEvaluationandReview
Technique(PERT) . . . . . . . . . . . . . . . . . . . . . . . . . . 157
11.3 DevelopScheduleControlPlan . . . . . . . . . . . . . . . . . . . . . . . 174
11.3.1 ChooseControlSubject . . . . . . . . . . . . . . . . . . . . . . . 174
11.3.2 EstablishStandardPerformance . . . . . . . . . . . . . . . . . 175
11.3.3 PlanandCollectAppropriateData . . . . . . . . . . . . . . . 175
11.3.4 SummarizeDataandEstablishActualPerformance . . . 175
11.3.5 CompareActualPerformancetoStandard . . . . . . . . . 176
11.3.6 ValidateControlSubject . . . . . . . . . . . . . . . . . . . . . . 176
11.3.7 TakeActiononDifference . . .. . . . . . . . . . . . . . . .. . 176
12 DevelopResourcesManagementPlan . . . . . . . . . . . . . . . . . . . . . . 179
12.1 DefiningResourceManagement . . . . . . . . . . . . . . . . . . . . . . . 179
12.2 ListtheResourcestoBeConsumedbytheProject . . . . . . . . . . 180
12.2.1 Labor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
12.2.2 Facilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
12.2.3 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
12.2.4 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
12.3 AssigntheResourcestoProjectActivities . . . . . . . . . . . . . . . . 185
12.4 PlanProjectTeamDevelopmentandManagement . . . . . . . . . . 186
13 DevelopQualityManagementPlan . . . . . . . . . . . . . . . . . . . . . . . . 189
13.1 DevelopQualityPlan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
13.1.1 CollectRequirements:V.O.P. . . . . . . . . . . . . . . . . . . 192
13.1.2 DefineQualityPlan . . . . . . . . . . . . . . . . . . . . . . . . . . 192
13.1.3 VerifyQualityPlan . . . . . . . . . . . . . . . . . . . . . . . . . . 194
13.1.4 ControlQualityPlan . . . . . . . . . . . . . . . . . . . . . . . . . 195