Ingeniero industrial

Foreword by

Michael L. George

The Lean Six Sigma GUIDE TO Doing More with Less
Cut Costs, Reduce Waste, and Lower Your Overhead

MARK O. GEORGE

The Lean Six Sigma Guide to Doing More with Less

The Lean Six Sigma Guide to Doing More with Less
Cut Costs, Reduce Waste, and Lower Your Overhead

M A R K O. G E O R G E

John Wiley & Sons, Inc.

Copyright # 2010 by Accenture.All rights reserved. Published by John Wiley & Sons, Inc., Hoboken, New Jersey. Published simultaneously in Canada. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, scanning, or otherwise, except as permitted under Section 107 or 108 of the 1976 United States Copyright Act,without either the prior written permission of the Publisher, or authorization through payment of the appropriate per copy fee to the Copyright Clearance Center, Inc., 222 Rosewood Drive, Danvers, MA 01923, (978) 750 8400, fax (978) 646 8600, or on the web at www.copyright.com. Requests to the Publisher for permission should be addressed to the Permissions Department, John Wiley & Sons, Inc., 111River Street, Hoboken, NJ 07030, (201) 748 6011, fax (201) 748 6008, or online at http://www.wiley.com/go/permissions. Limit of Liability/Disclaimer of Warranty: While the publisher and author have used their best efforts in preparing this book, they make no representations or warranties with respect to the accuracy or completeness of the contents of this book and specifically disclaim any impliedwarranties of merchantability or fitness for a particular purpose. No warranty may be created or extended by sales representatives or written sales materials. The advice and strategies contained herein may not be suitable for your situation. You should consult with a professional where appropriate. Neither the publisher nor author shall be liable for any loss of profit or any other commercial damages,including but not limited to special, incidental, consequential, or other damages. For general information on our other products and services or for technical support, please contact our Customer Care Department within the United States at (800) 762 2974, outside the United States at (317) 572 3993 or fax (317) 572 4002. Wiley also publishes its books in a variety of electronic formats. Somecontent that appears in print may not be available in electronic books. For more information about Wiley products, visit our web site at www.wiley.com. Library of Congress Cataloging in Publication Data: George, Mark O., 1960 The lean six sigma guide to doing more with less : cut costs, reduce waste, and lower your overhead / Mark O. George. p. cm. Includes bibliographical references and Index. ISBN:978 0 470 53957 6 (cloth) 1. Cost control. 2. Six sigma (Quality control standards). 3. Production control. 4. Industrial management. I. Title. HD47.3.G47 2010 658.4 0 013 dc22 2009052170 Printed in the United States of America. 10 9 8 7 6 5 4 3 2 1

Contents

Foreword Preface

xi xv xxi

Acknowledgments

Chapter 1 Why Use Lean Six Sigma to Reduce Cost?

1

Transactional Example: LeanSix Sigma Transforming Our Government 6 The Alloy of High Performance: Why Choose Lean Six Sigma to Reduce Cost? 6 Lean Six Sigma versus Traditional Cost-Cutting Tactics 9 Emerging Stronger Than Ever 14 Spotlight #1 How to Use This Book 17

Overview of Part I: Process Cost Reduction—a Focus on the Tools of Waste Elimination 18 Overview of Part II: Enterprise Cost Reduction—a Focus on Value,Speed, Agility and Competitive Advantage 19 Overview of Part III: Accelerating Deployment Returns—Getting More, Faster, from a Lean Six Sigma Deployment 20

Part I

Process Cost Reduction: A Focus on Waste Elimination
Introduction to Part 1 23

v

vi

Contents

Chapter 2 Find Cost Reduction Opportunities in Waste

25 27 37

The Seven Common Faces of Waste: TIMWOOD Using the Full...