Lean Sigma: A Practitioner's Guide

(No reviews yet) Write a Review
$16.52 - $17.11
UPC:
9780132390781
Maximum Purchase:
3 units
Binding:
Hardcover
Publication Date:
2006-10-20
Author:
Ian Wedgwood PhD
Language:
english
Edition:
1

Product Overview

The Practical, Easy-to-Use Guide to Lean Sigma Problem-Solving

Lean Sigma delivers resultsif you use the right tools and techniques. In Lean Sigma: A Practitioners Guide, Dr. Ian Wedgwood captures best-practice Lean Sigma experience from multiple projects and industries, helping any professional identify the solution that will work bestand implement it.

Wedgwoods exclusive project roadmaps present the fastest, most effective route to solving a wide range of problemsand explain why those solutions make sense. His discovery roadmaps help you identify potential Lean Sigma projects, even in processes where there are no obvious targets.

The heart of Lean Sigma is Wedgwood's 48 individual tools roadmaps : step-by-step instructions revealing exactly how and when to use all these Lean Sigma tools...

5 Whys

5S

Affinity

ANOVA

Boxplots

Capability tools

Cause & effect matrices

Chi-Square

Control charts

Critical path analyses

Customer tools

Demand tools

DOE tools

Fishbone diagrams

Handoff maps

KPOVs

Load charts

MSA tools

Multi-Cycle analyses

Multi-Vari studies

Murphys analyses

Normality tests

OEE

Pareto charts

Poka Yoke

Process FMEA

Process variables (I/O) maps

Project charter

Pull systems & Kanban

Rapid changeover

Regression

SIPOC

Spaghetti maps

SPC

Swimlane maps

Time tools

Whether youre a Green Belt, Black Belt, Master, Project Champion, Sponsor, Deployment Leader, or consultant, this book will help you use Lean Sigma to solve far more problems, far more rapidly, and far more effectively.

Dr. Ian Wedgwood, Executive Director of Sigma Breakthrough Technologies, has more than ten years of experience using, deploying, training, and consulting on Six Sigma and Lean Sigma. He has led and facilitated deployments in industries ranging from electronics and medical devices to chemicals and health care, and has trained and mentored numerous executives, champions, and belts. He holds a Ph.D. and First-Class Honors degree in Applied Mathematics from Scotlands St. Andrews University.

Chapter 1 Introduction 1

PART I PROJECT ROADMAPS TO SOLVE BUSINESS PROBLEMS

Chapter 2 DefineTools Roadmap Applied to the Beginning of All Projects 13

Chapter 3 Global Process Problems 23

A: On-Time Delivery Issues 23

B: Capacity of Process Is Too Low 27

C: RTY, Defects, Accuracy, Quality, Scrap, and Rework Issues 29

D: % Uptime Is Too Low 33

E: Pace of Process Too Slow 36

F: Process Has Enough Capacity, But Fails Intermittently 38

G: Process Has Enough Capacity, But Process Lead Time Is Too Long 41

H: Individual Steps Meet Takt, Global Process Does Not 44

I: Demand from the Customer Is Too Variable 47

J: Too Many Entity Types (Products) 51

K: High Schedule Variation 54

L: Measurement System Broken 60

M: Performance Characteristic Not Good Enough 63

N: Planned Maintenance Takes Too Long 64

O: Setup/Changeover Takes Too Long 65

P: Too Much Unplanned Maintenance 68

Q: Process Cant Make Product at All 72

R: Resource Usage Is Too High (Headcount Reduction) 75

S: Inventory Is Too High 78

T: Waste/Process Loss Too High 82

U: High Forecast Variation 85

V: Not Enough Sales 89

W: Backlog of Orders Is Too High 91

X: Payments Made to Suppliers Not Optimized 93

Y: Accounts Receivable Are Too High 95

Chapter 4 Individual Step Process Problems 99

Chapter 5 ControlTools Used at the End of All Projects 107

PART II ROADMAPS TO FIND PROJECTS WHERE NO OBVIOUS CANDIDATES EXIST

Chapter 6 DiscoveryTools Applied to Identify Projects 115

PART III ROADMAPS TO GUIDE IN THE PRACTICAL APPLICATION OF EACH LEAN SIGMA TOOL

Chapter 7 Tools 119

01: 5 Whys 119

02: 5S 122

03: Affinity 130

04: ANOVA 133

05: Box Plot 141

06: CapabilityAttribute 143

07: CapabilityContinuous 146

08: Cause & Effect (C&E) Matrix 153

09: Chi-Square 157

10: Control Charts 163

11: Critical Path Analysis 171

12: Customer Interviewing 174

13: Customer Requirements Tree 183

14: Customer Surveys 186

15: Demand Profiling 193

16: Demand Segmentation 196

17: DOEIntroduction 202

18: DOEScreening 213

19: DOECharacterizing 222

20: DOEOptimizing 237

21: Fishbone Diagram 249

22: Handoff Map 253

23: KPOVs and Data 257

24: Load Chart 268

25: MSAValidity 272

26: MSAAttribute 276

27: MSAContinuous 284

28: Multi-Cycle Analysis 294

29: Multi-Vari Studies 300

30: Murphys Analysis 306

31: Normality Test 308

32: Overall Equipment Effectiveness (OEE) 311

33: Pareto Chart 318

34: Poka Yoke (Mistake Proofing) 321

35: Process FMEA 325

36: Process Variables (Input/Output) Map 330

37: Project Charter 333

38: Pull Systems and Kanban 342

39: Rapid Changeover (SMED) 354

40: Regression 362

41: SIPOC 372

42: Spaghetti (Physical Process) Map 376

43: Statistical Process Control (SPC) 380

44: Swimlane Map 384

45: Test of Equal Variance 389

46: TimeGlobal Process Cycle Time 392

47: TimeIndividual Step Cycle Time 395

48: TimeProcess Lead Time 398

49: TimeReplenishment Time 401

50: TimeTakt Time 404

51: Total Productive Maintenance 408

52: t-Test1-Sample 411

53: t-Test2-Sample 416

54: t-TestPaired 422

55: Value Stream Map 423

Reviews

(No reviews yet) Write a Review