Leaner Six Sigma : making Lean Six Sigma easier and adaptable to current workplaces

251 Pages·2019·11.262 MB·English

by  Stern, Terra Vanzant

Leaner Six Sigma

Leaner Six Sigma

Making Lean Six Sigma Easier and
Adaptable to Current Workplaces
Terra Vanzant Stern, PhD
A PRODUCTIVITY PRESS BOOK
First edition published in 2019
by Routledge/Productivity Press
52 Vanderbilt Avenue, 11th Floor New York, NY 10017
2 Park Square, Milton Park, Abingdon, Oxon OX14 4RN, UK
© 2019 by Terra Vanzant Stern, PhD
Routledge/Productivity Press is an imprint of Taylor & Francis Group, an Informa business
No claim to original U.S. Government works
Printed on acid-free paper
International Standard Book Number-13: 9 78-1-138-38792-8 (Hardback)
978-0-429-42596-7 (eBook)
This book contains information obtained from authentic and highly regarded sources. Reasonable
efforts have been made to publish reliable data and information, but the author and publisher cannot
assume responsibility for the validity of all materials or the consequences of their use. The authors and
publishers have attempted to trace the copyright holders of all material reproduced in this publication
and apologize to copyright holders if permission to publish in this form has not been obtained. If any
copyright material has not been acknowledged please write and let us know so we may rectify in any
future reprint.
Except as permitted under U.S. Copyright Law, no part of this book may be reprinted, reproduced,
transmitted, or utilized in any form by any electronic, mechanical, or other means, now known or
hereafter invented, including photocopying, microfilming, and recording, or in any information
storage or retrieval system, without written permission from the publishers.
For permission to photocopy or use material electronically from this work, please access www.
copyright.com (http://www.copyright.com/) or contact the Copyright Clearance Center, Inc. (CCC),
222 Rosewood Drive, Danvers, MA 01923, 978-750-8400. CCC is a not-for-profit organization that
provides licenses and registration for a variety of users. For organizations that have been granted a
photocopy license by the CCC, a separate system of payment has been arranged.
Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are
used only for identification and explanation without intent to infringe.
Visit the Taylor & Francis Web site at
http://www.taylorandfrancis.com
and the CRC Press Web site at
http://www.crcpress.com
Dedication
To all the delightful clients and students who supported
my effort to make Lean Six Sigma, even Leaner!

Contents
Preface .................................................................................................xiii
Author .................................................................................................xvii
Section i the Basics—Making things
Better, Faster or More cost effective
chapter 1 What Is Process Improvement? .........................................3
chapter 2 A Brief History of Lean and Six Sigma .............................7
chapter 3 Agile ..................................................................................17
Recognized Certifications in Agile .........................................20
Agile Basic Tools and Techniques ............................................21
Scrum Model ..........................................................................21
Sprints ......................................................................................23
Sprint Retrospectives .............................................................23
Agile Stages .............................................................................24
Agile Manufacturing ..................................................................24
Agile Project Management ........................................................25
chapter 4 Project Management ........................................................27
Project Initiation .........................................................................29
Project Planning .........................................................................29
Project Execution .......................................................................30
Project Monitoring and Controlling ........................................31
Project Closing ............................................................................31
chapter 5 A Deeper Dive: Six Sigma and the DMAIC Model ........35
Define ...........................................................................................36
Measure ........................................................................................36
Analyze ........................................................................................37
Improve ........................................................................................37
vii
viii • Contents
Control .........................................................................................38
PDCA .......................................................................................38
Plan-Do-Check-Act Procedure ............................................39
SWOT Analysis ......................................................................39
5S ..............................................................................................39
Six Sigma ...........................................................................40
Lean ....................................................................................40
Summary Overview ..................................................................40
Section ii the DMAic Model
chapter 6 Define Overview ..............................................................45
DMAIC (Define-Measure-Analyze-Improve-Control) ........45
Elements of Define (DMAIC) ..................................................46
Project Charter ............................................................................47
Stakeholder Analysis ..................................................................47
High-Level Process Map ............................................................47
SIPOC Process Map ...................................................................47
Voice of the Customer ...............................................................48
Affinity Diagram ........................................................................49
Kano Model .................................................................................51
Critical-to-Quality (CTQ) Tree ................................................52
chapter 7 Measure Overview ...........................................................55
DMAIC (Define-Measure- Analyze-Improve-Control) ........55
Prioritization Matrix ..................................................................57
Process Cycle Efficiency .............................................................58
Time Value Analysis ...................................................................58
Pareto Charts...............................................................................58
Measurement Systems Analysis ................................................59
Control Charts ............................................................................61
Run Charts ..................................................................................62
Failure Modes and Effect Analysis (FMEA) ...........................63
chapter 8 Analyze Overview ............................................................65
DMAIC (Define-Measure-Analyze-Improve-Control) ........65
5 Whys Analysis .......................................................................66
Contents • ix
Key Concept ................................................................................67
Brainstorming .............................................................................67
Cause & Effect (C&E) Diagram ...............................................68
Flow Diagrams ............................................................................69
Regression Analysis ....................................................................71
Scatter Plots .................................................................................71
Variation ......................................................................................73
chapter 9 Improve Overview ............................................................77
DMAIC (Define-Measure-Analyze-Improve-Control) ........77
Setup Reduction ..........................................................................79
Key Concept............................................................................79
Queuing Methods for Reducing Congestion
and Delays ..........................................................................80
Kaizen ..........................................................................................80
Roles and Responsibilities ....................................................81
Basic Phases of Traditional Project Management .............82
chapter 10 Control Overview .............................................................85
DMAIC (Define-Measure-Analyze-Improve-Control) ........85
Control Charts ......................................................................86
FMEA Forms .........................................................................86
ROI Formulas .........................................................................87
Quality Control ......................................................................87
Standardization .....................................................................88
Responding When Defects Occur ......................................88
Section iii Standards
chapter 11 The Impact of ISO Standard 13053: Six Sigma on
the Leaner Approach ........................................................95
ISO 13053-1 .................................................................................97
ISO 13053-2 ...............................................................................101
chapter 12 ISO 21500—Guide to Project Management .................103
PMI Certifications ....................................................................110
PRINCE2® Certifications ........................................................111