About the Book
The Practical, Easy-to-Use Guide to Lean Sigma Problem-Solving
Lean Sigma delivers results--
if you use the right tools and techniques. In
Lean Sigma: A Practitioner's Guide, Dr. Ian Wedgwood captures best-practice Lean Sigma experience from multiple projects and industries, helping any professional identify the solution that will work best--
and implement it. Wedgwood's exclusive "project roadmaps" present the fastest, most effective route to solving a wide range of problems--and 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 - Murphy's 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 you're 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 Scotland's St. Andrew's University. Chapter 1 Introduction 1
PART I PROJECT ROADMAPS TO SOLVE BUSINESS PROBLEMS Chapter 2 Define--Tools 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 Can't 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 Control--Tools Used at the End of All Projects 107
PART II ROADMAPS TO FIND PROJECTS WHERE NO OBVIOUS CANDIDATES EXIST Chapter 6 Discovery--Tools 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: Capability--Attribute 143 07: Capability--Continuous 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: DOE--Introduction 202 18: DOE--Screening 213 19: DOE--Characterizing 222 20: DOE--Optimizing 237 21: Fishbone Diagram 249 22: Handoff Map 253 23: KPOVs and Data 257 24: Load Chart 268 25: MSA--Validity 272 26: MSA--Attribute 276 27: MSA--Continuous 284 28: Multi-Cycle Analysis 294 29: Multi-Vari Studies 300 30: Murphy's 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: Time--Global Process Cycle Time 392 47: Time--Individual Step Cycle Time 395 48: Time--Process Lead Time 398 49: Time--Replenishment Time 401 50: Time--Takt Time 404 51: Total Productive Maintenance 408 52: t-Test--1-Sample 411 53: t-Test--2-Sample 416 54: t-Test--Paired 422 55: Value Stream Map 423
