Implementing Lean Six Sigma Throughout the Supply Chain
by Cudney, Elizabeth A.; Kestle, RodneyFormat: Paperback
Pub. Date: 2010-10-14
Publisher(s): Productivity Pr
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Summary
From start to finish, this book provides a comprehensive lean six sigma case study. The text follows a team as they implement a lean six sigma project and provides over illustrative 100 figures and tables. Unlike current published case studies, which give only an overview, this in-depth case study presents the data, which are also included in the accompanying CD, and comprehensively explains how the team drew their conclusions. The CD contains all of the data used throughout the case study, so that readers can make the same analyses. In addition, the authors demonstrate the clear linkages between all of the lean six sigma tools.
Table of Contents
| Acknowledgments | p. xi |
| Authors | p. xiii |
| Introduction | p. 1 |
| How To Use the CD | p. 2 |
| CD Instructions | p. 2 |
| Lean Six Sigma Overview | p. 5 |
| Case Study Introduction | p. 11 |
| Define Phase | p. 15 |
| Introduction | p. 15 |
| Midwest Logistics, Lean Six Sigma Core Team | p. 16 |
| Develop Initial Documents | p. 19 |
| Project Charter | p. 20 |
| Supplier-Input-Process-Output-Customer (SIPOC) | p. 25 |
| Identify Stakeholders and Develop Communication Plan | p. 28 |
| Communications Strategy List | p. 32 |
| Perform Initial VOC and Identify CTS | p. 35 |
| Select the Team and Launch the Project | p. 39 |
| Midwest Logistics, Lean Six Sigma Team Additions | p. 40 |
| Create Responsibility Matrix (RASIC) | p. 41 |
| Create Project Plan | p. 41 |
| Measure Phase | p. 55 |
| Introduction | p. 55 |
| Define the Current Process | p. 56 |
| Process Mapping | p. 64 |
| Data Collection Plan, Metrics, and Operational Definitions | p. 84 |
| Create a Baseline | p. 97 |
| Define the Detailed Voice of the Customer (VOC) | p. 101 |
| Interview Event | p. 101 |
| Brainstorm Needs | p. 104 |
| Affinity Diagrams | p. 105 |
| Translate Needs to CTQ | p. 108 |
| Survey Customers/Stakeholders | p. 115 |
| Customer Needs Map | p. 116 |
| Quality Function Deployment (QFD) | p. 138 |
| Define the Voice of the Process (VOP) and Current Performance | p. 139 |
| Benchmarking | p. 141 |
| Check Sheets | p. 141 |
| Plots, Capability and Statistics | p. 148 |
| Pareto Charts, Time Series, Histograms | p. 149 |
| Validate Measurement System | p. 159 |
| Define the Cost of Poor Quality (COPQ) and Cost/Benefit | p. 164 |
| Moving to the Analyze Phase | p. 164 |
| Analyze Phase | p. 167 |
| Introduction | p. 167 |
| Develop Cause-and-Effect Relationships | p. 169 |
| Test for Normality Exercise | p. 172 |
| Process Analysis and 8 Wastes | p. 173 |
| 5S | p. 176 |
| Failure Mode and Effects Analysis | p. 177 |
| Determine and Validate Root Causes | p. 181 |
| Regression Analysis | p. 196 |
| Hypothesis Test | p. 196 |
| Develop Process Capability | p. 196 |
| Process Capability | p. 199 |
| Improve Phase | p. 207 |
| Introduction | p. 207 |
| Identify Breakthrough and Select Practical Approaches | p. 208 |
| Action (Pilot) Plan | p. 210 |
| Perform Cost/Benefit Analysis | p. 211 |
| Design Future State | p. 212 |
| Establish Performance Targets and Project Scorecard | p. 214 |
| Gain Approval to Implement, Then Implement | p. 222 |
| Train and Execute | p. 222 |
| Control Phase | p. 231 |
| Introduction | p. 231 |
| Measure Results and Manage Change | p. 232 |
| Report Scorecard Data and Create Process Control Plan | p. 235 |
| FMEA and Control Plan | p. 235 |
| Process Capability/DPMO | p. 237 |
| Apply P-D-C-A Process | p. 240 |
| Identify Replication Opportunities | p. 242 |
| Develop Future Plans | p. 244 |
| Conclusions | p. 247 |
| Lean Six Sigma Glossary | p. 249 |
| Index | p. 261 |
| Table of Contents provided by Ingram. All Rights Reserved. |
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