The Six Sigma Project Planner A Step-by-Step Guide to Leading a Six Sigma Project Through DMAIC

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ISBN: 9780071411837 | 0071411836
Cover: Paperback
Copyright: 4/11/2003

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The Six Sigma Project Planner is designed to be used by the leaders of a Six Sigma initiative, to plan and implement prioritized Six Sigma projects. It guides leaders through selecting the quality improvement projects that will have the biggest payoff, measuring and analyzing a problem, and implementing solutions. Teams who are assigned projects will use the Six Sigma Project Planner to plan and manage individual projects. The Planner follows the Define-Measure-Analyze-Improve- Control (DMAIC) Six Sigma format for process improvement, and enables organizations to take a project management approach to a Six Sigma roll-out.

List of Figures	p. viii
List of Tables	p. ix
List of Worksheets	p. ix
Preface	p. xiii
Introduction	p. xiv
How to Use The Six Sigma Planner	p. xiv
Planning	p. 1
Develop the Project Charter	p. 1
Project Charter	p. 1
The Project Charter Document	p. 1
Conduct a Feasibility Analysis	p. 5
Is This a Valid Project	p. 5
Feasibility Analysis Study	p. 8
The Project Plan	p. 16
Project Metrics	p. 16
Refining the Dollar Opportunity Estimates	p. 20
How Will I Monitor Satisfaction with Project Success?	p. 22
Identify Human Resources Need to Complete the Project	p. 24
Identify Other Resources Needed to Complete the Project	p. 27
Work Breakdown Structures	p. 29
Creating the WBS	p. 29
Integration and Test	p. 32
Project Schedule Development	p. 32
Activity Definition	p. 35
Activity Dependencies	p. 38
Estimating Activity Duration	p. 40
Gantt Charts	p. 42
Network Diagrams	p. 46
Resource Availability	p. 51
Calendars	p. 51
Schedule Improvement	p. 54
Estimating Project Duration Statistically	p. 60
Calculating the Cost of a Schedule	p. 66
Resource Leveling	p. 70
Project Control Subplans	p. 72
Risk Control Plan	p. 72
Quality Plan	p. 80
Cost Control Plan	p. 84
Schedule Control Plan	p. 87
Project Schedule Management	p. 88
Scope Change Control Plan	p. 90
Change Control System	p. 90
Define	p. 95
What Is the Current State?	p. 95
What's Wrong with the Way Things are Now?	p. 96
Quantify the Undesirable Effects	p. 97
Tools and Techniques	p. 97
Failure Mode and Effect Analysis (FMEA)	p. 100
FMEA Process	p. 100
Process Metrics	p. 106
Other Key Factors and Metrics	p. 110
How Does This Project Move the Organization Toward Its Strategic Goals and Objectives?	p. 111
Measure
Measurement Reliability and Validity	p. 113
Dimension Measurement Analysis	p. 113
Attribute Measurement Analysis	p. 115
Analyze	p. 119
Quantify the Current Process	p. 119
Catalog of Data Sources for This Process	p. 119
Exploratory Data Analysis	p. 121
Descriptive Data Analysis	p. 122
Example of Using Worksheet	p. 124
Quantify the Capability of the Current Process	p. 125
Conduct a Process Audit	p. 125
Prepare an Audit Report	p. 129
Determine Sigma and DPMO Levels CTx's	p. 129
Process Capability and Process Actual Sigma Levels Continuous CTx Characteristics	p. 129
Measuring Process Capability for Variables Data	p. 129
Measuring Actual Process Performance for Variables Data	p. 130
Process Capability and Process Actual Sigma Levels for Attribute CTx Characteristics	p. 131
Measuring Process Capability for Attributes Data	p. 132
Measuring Actual Process Performance for Variables Data	p. 132
Improve	p. 139
Optimize the Process	p. 139
Perform Designed Experiments	p. 141
What Will the Future State Be?	p. 144
What are the Best Practices in This Area?	p. 144
Create a Future State Process Map	p. 150
Six Sigma Project Activities Template	p. 152
Presentation and Acceptance of Deliverables	p. 154
Control	p. 157
Control Failure Mode and Effect Analysis (FMEA)	p. 157
Business Process Control Systems	p. 159
How Will We Maintain the Gains Made?	p. 159
A Tutorial on Project Selection and Management	p. 165
Choosing the Right Projects	p. 165
Customer Value Projects	p. 166
Using QFD to Link Six Sigma Projects to Strategies	p. 166
The Strategy Deployment Plan	p. 168
Using Customer Demands to Design For Six Sigma	p. 174
Structured Decision-Making	p. 175
Shareholder Value Projects	p. 184
Other Six Sigma Projects	p. 184
Analyzing Project Candidates	p. 184
Other Methods of Identifying Promising Projects	p. 184
Using Pareto Analysis to Identify Six Sigma Candidates	p. 185
Throughput-Based Project Selection	p. 186
Multitasking and Project Scheduling	p. 190
Critical Chain Project Portfolio Management	p. 191
Summary and Preliminary Project Selection	p. 192
Tracking Six Sigma Results	p. 194
Financial Results Validation	p. 196
Types of Savings	p. 196
Lessons Learned: Capture and Replication	p. 196
Appendices	p. 199
Issues List	p. 200
Risk Control Plan	p. 202
Quality Plan	p. 203
Cost Control Plan	p. 204
Schedule Control Plan	p. 205
Project Change Control Plan	p. 206
Audit Report	p. 207
Business Process Change Control Plan	p. 208
Resource Calendars	p. 209
Attribute Measurement Error Analysis	p. 210
Calculating Yields	p. 224
Normalized Yield and Sigma Level	p. 227
Analytic Hierarchy Process (AHP) Using MS Excel	p. 230
Additional Resources on Six Sigma Project Management	p. 232
Figures
The Six Sigma Project Process Flow	p. xv
Map of Six Sigma Project Flow	p. xvii
Six Sigma Project DMAIC Cycle Questions	p. xviii
Example of Project Validation Analysis	p. 6
Example of Cost-Benefit Opportunity Calculations	p. 20
WBS Creation Process Flowchart	p. 29
Example of a WBS	p. 30
Types of Activity Dependencies	p. 38
Gantt Chart of Schedule	p. 42
Gantt/Milestone Chart of Actual vs. Scheduled Performance	p. 42
Example of Computer Gantt/Milestone Chart	p. 43
Example of Network Diagram	p. 48
Example of a Computer-Generated Network Diagram	p. 49
Example of a Computer-Generated Human Resource Calendar	p. 52
Computer Screen for Entering Task Duration Data	p. 63
Results of Simulation for Example	p. 64
Simulation Results: Probability of Meeting Due Date	p. 65
Example of Cross-Functional Process Map	p. 95
Define Gate Criteria	p. 112
Measure Gate Criteria	p. 118
Some EDA Techniques	p. 121
Example of Combined DDA and EDA Analysis	p. 122
Example of Evaluating a Hypothesis	p. 124
Analyze Gate Criteria	p. 137
Example of a Future State Process Map	p. 150
Improve Gate Criteria	p. 156
Control Gate Criteria	p. 164
Strategy Deployment Plan	p. 167
Strategy Deployment Matrix	p. 168
QFD Relationship Weights and Symbols	p. 169
Phase II Matrix: Differentiators	p. 171
Phase III Matrix: Six Sigma Projects	p. 173
Linkage Between Six Sigma Projects and Stakeholders	p. 174
Customer Demand Model	p. 178
Matrix of Categories for Pairwise Comparisons	p. 180
Completed Top-Level Comparison Matrix	p. 181
A Simple Process with a Constraint	p. 187
Critical Chain Scheduling Illustration	p. 193
Lithography Inspection Station Table, Stool, and Magnifying Glass	p. 215
Attribute Gauge R&R Dialog Box and Data Layout	p. 219
MINITAB "Agreement Within Appraiser"	p. 220
Plot of "Agreement Within Appraiser"	p. 220
MINITAB "Agreement of Appraiser with Standard"	p. 221
Plot of "Agreement of Appraiser with Standard"	p. 221
MINITAB "Appraiser Disagreement"	p. 222
MINITAB "Agreement Between Appraisers"	p. 222
MINITAB "Assessment vs. Standard Agreement Across All Appraisers"	p. 223
Excel Spreadsheet for RTY	p. 225
Excel Spreadsheet for Calculating Normalized Yield	p. 227
Finding RTY Using Simulation Software	p. 229
Tables
Instructions for Completing the Project Charter Statement Form	p. 4
Strategies for Meeting the Project Goals	p. 24
Tools Useful in Risk Assessment	p. 75
Risk Planning vs. Impact and Likelihood of Threatening Events	p. 75
Risk Response Planning Tools	p. 78
FMEA Severity, Likelihood, Detectibility Rating Guidelines	p. 102
FMEA Information	p. 104
Phases in Process Optimization	p. 141
Typical DMAIC Project Tasks and Responsibilities	p. 152
Local and Global Importance Weights	p. 182
Example of Using Global Weights in Assessing Alternatives	p. 183
Dysfunctional Process Symptoms and Underlying Diseases	p. 185
Illustration of the Pareto Priority Index (PPI)	p. 186
Throughput Priority of CTx Projects That Affect the Constraint	p. 189
Project Throughput Priority vs. Project Focus	p. 189
Possible Information to Be Captured	p. 195
A Typical View of Six Sigma Projects	p. 195
Attribute Measurement Concepts	p. 210
Methods of Evaluating Attribute Inspection	p. 213
Results of Lithography Attribute Inspection Study	p. 215
Inspector Accuracies	p. 216
Repeatability and Pairwise Reproducibility for Both Days Combined	p. 216
Stability Analysis	p. 217
Calculations Used to Find RTY	p. 224
Worksheets
Project Charter Statement	p. 2
Project Validation Analysis	p. 7
Six Sigma Project Evaluation	p. 9
Six Sigma Project Evaluation Guidelines	p. 10
Project Budget Development	p. 17
Deliverables Metrics	p. 19
Dollar Opportunity Estimate	p. 21
Project Progress Satisfaction Metrics	p. 23
Human Resources Assessment	p. 26
Project Resource Planning	p. 28
Project Work Breakdown Structure	p. 31
List of Penalties for Missing Deadline	p. 33
Major Milestones and Target Dates	p. 34
Historical Research Summary	p. 36
Constraint Analysis	p. 37
Activity Dependenciesa	p. 39
Activity Duration Estimates	p. 41
List of Activities	p. 44
Project Gantt/Milestone Chart Template	p. 45
Project Gantt/Milestone Chart (Freehand Drawing Format)	p. 46
Network Diagram for Project	p. 50
Resource Availability Information	p. 53
Schedule Improvement Evaluation	p. 55
Best-Case, Expected, and Worst-Case Schedule Completion Dates	p. 59
Statistical Analysis of Project Duration	p. 62
Estimated Cost by Activity Duration	p. 67
Cost-Optimization Spreadsheet Results	p. 68
Cost-Optimization Graphical Analysis	p. 69
Resource Leveling	p. 71
Risk Event Classification	p. 76
New Opportunities	p. 77
Risk Response Plans	p. 79
Quality Plan Items	p. 82
Project Budget Reports and Reporting Frequency	p. 86
Activity Status Management Report	p. 89
Change Control Information	p. 90
Controlled Documents List	p. 90
Current Process Map	p. 96
Narrative Description of Undesirable Effects	p. 96
Undesirable Effects	p. 99
FMEA Worksheet	p. 105
CTQ Characteristics	p. 108
CTS and CTC Characteristics	p. 109
Other Key Factors and Metrics	p. 110
Linkages to Enterprise Strategic Goals	p. 111
Gauge R&R Results	p. 114
Attribute Inspection System Results	p. 116
Attribute Inspection Results by Inspector	p. 117
Information Resource Catalog	p. 120
DDA/EDA-Based Theories to Investigate Further	p. 123
Process Audit Check Sheet	p. 126
Actual CTx DPMO and Sigma Levels	p. 134
Capability Levels of Performance	p. 135
Rolled Throughput Yield Analysis	p. 136
Optimum Levels of Performance	p. 142
Optimum Rolled Throughput Yields	p. 143
Benchmarking Step 1: Identify What Is to Be Benchmarked	p. 144
Benchmarking Step 2: Identify Comparative Companies	p. 145
Benchmarking Step 3: Determine Data Collection Methods	p. 146
Benchmarking Step 4: Collect Data on Benchmark	p. 147
Benchmarking Step 5: Determine the Current Performance Gap	p. 148
Benchmarking Step 6: Identify Causes of the Performance Gap	p. 148
Benchmarking Step 7: Estimate Future Performance Levels	p. 149
Benchmarking Step 8: Establish Functional Goals and Gain Acceptance of Stakeholders	p. 149
Alternative Future State Process Maps	p. 151
Future State Improvement Estimates	p. 151
Deliverables Acceptance Report	p. 155
Control FMEA Worksheet	p. 158
Additional Business Process Change Control Mechanisms	p. 162
Project Assessment Summary	p. 194
Issues List	p. 200
Rolled Throughput Yields Worksheet	p. 226
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The Six Sigma Project Planner A Step-by-Step Guide to Leading a Six Sigma Project Through DMAIC

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