Lean Six Sigma Using SigmaXL and Minitab

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Lean Six Sigma: Using SigmaXL and Minitab

Lean Six Sigma: Using SigmaXL and Minitab provides a complete guide to Lean Six Sigma statistical and analytical methods, plus coverage of SigmaXL and Minitab, two of today's most popular analytical programs. Filled with more than 100 real-life examples, this expert resource covers Lean topics ranging from basic data analysis to complex Design of Experiment and Measurement System Analysis. Readers will learn about tools used in Lean Six Sigma such as Statistical Process Control, Taguchi Method, and Process Capability Analysis, and get practice examples on an affiliated website.

List Price $29.95
Website Price $26.96

Author: Issa Bass
Format: Softcover
Copyright: 2009
Pages: 384

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Description

Lean Six Sigma is the most effective methodology for enhancing business performance through quality improvement and customer satisfaction. This book provides a complete guide to Lean Six Sigma statistical and analytical methods, plus coverage of SigmaXL and Minitab, two of today's most popular analytical programs. Filled with more than 100 real-life examples, this expert resource covers Lean topics ranging from basic data analysis to complex Design of Experiment and Measurement System Analysis. Readers will learn about tools used in Lean Six Sigma such as Statistical Process Control, Taguchi Method, and Process Capability Analysis, and get practice examples on an affiliated website.

Effectively Execute Lean Six Sigma Projects Using SigmaXL and Minitab

Written by a Six Sigma Master Black Belt and a Ph.D., this practical guide to Lean Six Sigma project execution follows the DMAIC (Define, Measure, Analyze, Improve, and Control) roadmap. The many real-world examples used in the book offer in-depth theoretical analyses and are implemented using the two most popular statistical software suites – SigmaXL and Minitab. This expert resource covers Lean topics ranging from basic data analysis to complex design of experiments and statistical process control. Harness the power of SigmaXL and Minitab and enable sustained positive operational results throughout your organization with help from this authoritative guide.

Lean Six Sigma using SigmaXL and Minitab explains how to:

Define the project goals, project manager, value statement, stakeholders, and risk.
Schedule tasks using the Gantt chart, critical path analysis, and program evaluation and review technique.
Capture the voice of internal and external customers.
Assess the cost of quality.
Gather data and measure process performance.
Perform process capabilities analysis.
Apply Lean Six Sigma metrics to determine baseline performance.
Implement analysis techniques such as Pareto analysis, value stream mapping, failure mode and effect analysis (FMEA), and regression analysis.
Identify constraints via factorial experiments, and implement process improvements.
Monitor production performance using statistical process control.

From the Preface
Business production methodologies have never stopped improving since Frederick W. Taylor, the inventor of scientific management, devised techniques for factory management and time and motion studies. Eli Whitney created the methods for interchangeable parts and Henry Ford developed the modern assembly lines used in mass production today. These inventions were the precursors of the modern day quality and productivity improvement methodologies. Over the past three decades, many managerial methodologies aimed at improving production processes have been introduced to businesses throughout the world. Some have resisted skepticism and have prevailed and are still being used, while others, such as the total quality management (TQM) or company wide quality control (CWQC), have been deemed to be nothing but fads and have disappeared almost immediately after they appeared. In fact, all the process improvement strategies (Six Sigma, TQM, CWQC, Lean, TOC, etc.) have the same underlying philosophy; they are all geared toward customer satisfaction and insist on the necessity for all sections of a company to cooperate in order to improve all aspects of its operations They all insist on producing high-quality products at the lowest possible cost through a reduction of waste and continuous improvement.

Some companies have deployed TQM and failed because the deployment was conducted badly, their employees were poorly trained, or the areas they insisted on improving were areas that did not require improvement because their improvement would not have had a positive impact on the overall performance of the business. This costs money and does not generate any significant return on investment.

In most cases, TQM did not fail because it was in itself a bad methodology or that its application was conducive to poor performance and failure. In fact, the name of the methodology that a company uses to improve its processes should not be the most germane aspect of its management strategy. Currently, the most widespread methodologies used in management are Six Sigma and Lean, also known as the Toyota Production System (TPS).

Indeed, most of the tools that were used by TQM have been refined and are still being used in Six Sigma. Six Sigma and Lean have withstood skepticism largely because of the success some major corporations have seen as a direct result of their application. A careful observation of those corporations would reveal that Six Sigma and Lean are not partially used and, in most cases, they have become a culture, a way of managing for those companies instead of auxiliary instruments temporarily used to solve a circumstantial problem.

Six Sigma is a data-driven business strategy that seeks to streamline production processes to constantly generate quasi-perfect products and services in order to achieve breakthrough return on investment. One of the pillars of Six Sigma is the pursuit of the reduction of production process variation to an infinitesimal level.

Lean manufacturing or TPS is a management methodology originated in Japan and more often associated with Toyota Motor Company; it was introduced to the American public by James Womack and Daniel T. Jones in the 1990s. It is about doing things right the first time and every time at a steady pace. It is also about reducing cycle time and inventory by eliminating waste. The underlying foundation of Lean manufacturing is the organizational strategy that constantly seeks a continuous improvement through the identification of the non-value-added activities (Muda) and their elimination along with the reduction of the time it takes to perform the value-added tasks.

Most companies use these two methodologies simultaneously for process improvement because, taken in isolation, each of these methodologies can yield good results. However, when they are combined, the probability for success is even greater.

This book is written as a practical introduction to Lean Six Sigma project execution and follows the DMAIC (define, measure, analyze, improve, and control) roadmap. It is written in such a way that it can be used as a training text for beginners and a reference for seasoned practitioners. Six Sigma is, by definition, analytical and profoundly rooted in statistical analysis. Therefore, ample statistical theory and development are provided to support the analyses. Both a theoretical analysis and the two most widely used statistical software suites, SigmaXL and Minitab, are used throughout the examples to help the reader better understand how to execute a Lean Six Sigma project.

The book is based on years of teaching the Lean and Six Sigma methodologies to a wide variety of audiences from different industries. We hope that the content of the book will be helpful in furthering the understanding of Lean Six Sigma project execution.

Table of Contents
Preface. Acknowledgments. Introduction. An Overview of SigmaXL. Chapter 1: Define. Chapter 2: Measure. Chapter 3: Analyze. Chapter 4: Improve. Chapter 5: Control. Appendix. Tables. Table A.1: Binomial. Table A.2: Poisson. Table A.3: Chi Square. Table A.4: Z Table. Table A.5: tTable. Table A.6: F Table. Index.

About the Authors
Issa Bass is a Master Black Belt and senior consultant with Manor House and Associates. He is the founding editor of SixSigmaFirst.com. Bass has extensive experience in quality and operations management, and is the author of Six Sigma Statistics with Minitab and Excel.
Barbara Lawton PhD is a Six Sigma Black Belt and has been improving manufacturing processes using Lean techniques and Six Sigma for more than 15 years, in various industries on three continents. Dr. Lawton specializes in data analysis, and is a keen experimentalist and problem solver, using a wide range of statistical tools. She currently works for one of the world's leading aerospace organizations in the UK.

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