Six Sigma

Six Sigma: Continual Improvement for Businesses

Six Sigma: Continual Improvement for Businesses
A Practical Guide

William T. Truscott
Ph.D., B.Sc. (Eng.), C.Eng., M.I.Mech.E., M.I.E.E., M.R.Ae.S., F.S.S., F.I.Q.A.

AMSTERDAM BOSTON HEIDELBERG LONDON NEW YORK OXFORD PARIS SAN DIEGO SAN FRANCISCO SINGAPORE SYDNEY TOKYO

Butterworth-Heinemann An imprint of Elsevier Linacre House,Jordan Hill, Oxford OX2 8DP 200 Wheeler Road, Burlington, MA 01803 First published 2003 Copyright © 2003, William Truscott. All rights reserved The right of William Truscott to be identified as the author of this work has been asserted in accordance with the Copyright, Designs and Patents Act 1988 No part of this publication may be reproduced in any material form (including photocopying or storing inany medium by electronic means and whether or not transiently or incidentally to some other use of this publication) without the written permission of the copyright holder except in accordance with the provisions of the Copyright, Designs and Patents Act 1988 or under the terms of a licence issued by the Copyright Licensing Agency Ltd, 90 Tottenham Court Road, London, England W1T 4LP.Applications for the copyright holder's written permission to reproduce any part of this publication should be addressed to the publisher Permissions may be sought directly from Elsevier’s Science and Technology Rights Department in Oxford, UK: phone: (+44) (0) 1865 843830; fax: (+44) (0) 1865 853333; e-mail: permissions@elsevier.co.uk. You may also complete your request on-line via the Elsevier homepage(http://www.elsevier.com), by selecting ‘Customer Support’ and then ‘Obtaining Permissions’ British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library Library of Congress Cataloguing in Publication Data A catalogue record for this book is available from the Library of Congress ISBN 0 7506 57650 For information on all Butterworth-Heinemannpublications visit our website at www.bh.com

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Contents

Preface Chapter 1 What is Six Sigma? Six Sigma in perspective Principal facets of Six Sigma Six Sigma: the statistical model Six Sigma: the improvement process Chapter highlights Why should organizations implement Six Sigma? Response to change:competition: waste Results achieved by organizations already committed to Six Sigma Response to competition Improving employee involvement and engagement Continuing high cost of quality Recognition that other improvement initiatives have been fragmented or short-lived Chapter highlights How does Six Sigma compare with other improvement initiatives? Overview Which strategy to deploy?

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Chapter 2

Chapter 3

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vi Contents

ISO 9000:2000 family of quality systems standards Quality excellence models: total quality management The role of the US gurus The role of the Japanese gurus in Six Sigma Chapter highlights Chapter 4 How can Six Sigma achieve the greatest impact on business performance? Common aim of Six Sigma projects What isvalue? How to enhance value throughout the organization Six Sigma for high-value design Axiomatic design Quality function deployment TRIZ Taguchi quality engineering Value analysis Potential failure mode and effects analysis Chapter highlights Chapter 5 What competencies are required to drive Six Sigma? What is meant by competency? Competencies for Six Sigma – overview Organizational-widedeployment competencies Business process management competencies Project management competencies Six Sigma improvement tools: competencies Lean organization competencies Design for Six Sigma competencies Chapter highlights

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Chapter 6 What are the options for tailoring and implementing Six Sigma? What...