The Lean Six Sigma Pocket Toolbook: A Quick

Bestselling Lean Six Sigma author Michael George provides the first pocket guide for deployers of Lean Six Sigma The Lean Six Sigma Pocket Toolbookblends Lean and Six Sigma tools and concepts, providing expert advice on how to determine which tool within a "family" is best for different purposes. Packed with detailed examples and step-bystep instructions, it's the ideal handy reference guide to help Green and Black Belts make the transition from the classroom to the field. Features brief summaries and examples of the 70 most important tools in Lean Six Sigma, such as "Pull," "Heijunka," and "Control Charts" Groups tools by purpose and usage Offers a quick, easy reference on using the DMAIC improvement cycle Provides comprehensive coverage in a compact, portable format

Michael L. George (Dallas, TX) is the president of George Group and author of Lean Six Sigma and Lean Six Sigma for Service. John Maxey is a director at George Group. David Rowlands is the vice president of Lean Six Sigma for the North American Solutions Group, the sales, service, and marketing arm of Xerox. Malcolm Upton is a Lean Six Sigma Master Black Belt with George Group.

Chapter 1: Using DMAIC to Improve Speed, Quality, and Cost

1

(26)

Define

4

(4)

Measure

8

(4)

Analyze

12

(2)

Improve

14

(3)

Control

17

(3)

Kaizen DMAIC

20

(6)

Project selection

26

(1)

Chapter 2: Working With Ideas

27

(6)

Brainstorming

27

(3)

Affinity diagrams

30

(1)

Multivoting

31

(2)

Chapter 3: Value Stream Mapping and

Process Flow Tools

33

(1)

Process mapping

34

(2)

Process observation

36

(2)

SIPOC

38

(1)

Process mapping steps

39

(3)

Transportation and spaghetti (workflow) diagrams

42

(1)

Swim-lane (deployment) flowcharts

43

(2)

Value stream maps (basic)

45

(4)

Flowchart and value stream symbols

49

(1)

Value-add (VA) vs. non-value-add (NVA) analysis

49

(3)

Time value maps

52

(1)

Value-add chart (task time or take time chart)

53

(2)

Chapter 4: Voice of the Customer (VOC)

55

(14)

Customer segmentation

56

(2)

Sources of customer data

58

(1)

Collecting VOC: Interviews

59

(1)

Collecting VOC: Point-of-use observation

60

(1)

Collecting VOC: Focus groups

61

(1)

Collecting VOC: Surveys

62

(2)

Kano analysis

64

(3)

Developing critical-to-quality requirements

67

(2)

Chapter 5: Data Collection

69

(35)

Types of data

70

(1)

Input vs. output data

71

(1)

Data collection planning

72

(2)

Measurement selection matrix

74

(1)

Stratification factors

75

(1)

Operational definitions

76

(1)

Cautions on using existing data

77

(1)

Making a checksheet

78

(1)

Basic checksheets

79

(1)

Frequency plot checksheet

80

(1)

Traveler checksheet

80

(1)

Location checksheet

81

(1)

Sampling basics

81

(2)

Factors in sample selection

83

(1)

Stable process (and population) sampling

84

(1)

Formulas for determining minimum sample size (population or stable process)

85

(2)

Measurement System Analysis (MSA) and Gage R&R Overview

87

(1)

Gage R&R: Collecting the data

88

(2)

Interpreting Gage R&R Results

90

(6)

MSA: Evaluating bias

96

(1)

MSA: Evaluating stability

97

(2)

MSA: Evaluating discrimination

99

(1)

MSA for attribute/discrete data

100

(4)

Chapter 6: Descriptive Statistics and Data Displays

104

(13)

Statistical term conventions

105

(1)

Measures of central tendency (mean, median, mode)

106

(2)

Measures of spread (range, variance, standard deviation)

108

(2)

Boxplots

110

(1)

Frequency plot (histogram)

111

(3)

Normal distribution

114

(1)

Non-normal distributions and the Central Limit Theorem

114

(3)

Chapter 7: Variation Analysis

117

(24)

Review of variation concepts

118

(1)

Time series plots (Run charts)

119

(2)

Run chart table

121

(1)

Control chart basics

122

(1)

Selecting a control chart

123

(1)

Control charts for continuous data

123

(2)

Subgrouping for continuous data

125

(2)

Control limit formulas for continuous data

127

(1)

Factors for Control Chart Formulas

128

(1)

Creating an ImR Chart

128

(1)

Creating X,R charts or X,S charts

129

(1)

Control charts for attribute data

130

(2)

Creating p-, np-, c-, and u-charts

132

(1)

Control limit formulas for attribute data

132

(1)

Assumptions for interpreting control charts

133

(1)

Interpreting control charts (Tests for Special Cause Variation)

133

(2)

Background on process capability calculations

135

(2)

Confusion in short-term vs. long-term process capability calculations

137

(1)

Calculating process capability

138

(3)

Chapter 8: Identifying and Verifying Causes

141

(56)

PART A: Identifying potential causes

141

(8)

Pareto charts

142

(3)

5 Whys

145

(1)

Cause-and-effect diagrams (fishbone or Ishikawa diagrams)

146

(2)

C&E Matrix

148

(1)

PART B: Tools for confirming causal effects

149

(48)

Stratified data charts

150

(2)

Testing quick fixes or obvious solutions

152

(2)

Scatter plots

154

(2)

Hypothesis testing overview

156

(1)

Confidence intervals

157

(1)

Type I and Type II errors, Confidence, Power, and p-values

158

(2)

Confidence intervals and sample size

160

(1)

t-test Overview

161

(1)

1-Sample t-test

162

(1)

2-Sample t-test

163

(2)

Overview of correlation

165

(1)

Correlation statistics (coefficients)

166

(1)

Regression overview

167

(1)

Simple linear regression

168

(1)

Multiple regression

169

(4)

ANOVA (ANalysis Of VAriance)

173

(1)

One-way ANOVA

174

(4)

Degrees of Freedom

178

(1)

ANOVA assumptions

179

(1)

Two-way ANOVA

180

(2)

Chi-Square test

182

(2)

Design of Experiments (DOE) notation and terms

184

(1)

Planning a designed experiment

185

(4)

DOE: Full-factorial vs. Fractional-factorials (and notations)

189

(3)

Interpreting DOE results

192

(3)

Residual analysis in hypothesis testing

195

(2)

Chapter 9: Reducing Lead Time and Non-Value-Add Cost

197

(44)

Basic Lean concepts

199

(2)

Metrics of time efficiency

201

(2)

Time Traps vs. Capacity Constraints

203

(1)

Identifying Time Traps and Capacity Constraints

204

(2)

5S Overview

206

(1)

Implementing 5S

207

(6)

Generic Pull System

213

(3)

Replenishment Pull Systems

216

(3)

Two-Bin Replenishment System

219

(3)

Computing minimum safe batch sizes

222

(1)

Four Step Rapid Setup Method

223

(4)

Adapting Four Step Rapid Setup for service processes

227

(1)

Total Productive Maintenance (TPM)

228

(4)

Mistake proofing & prevention (Poky yoke)

232

(2)

Process balancing design principles

234

(1)

Work cell optimization

235

(2)

Visual Process Controls

237

(4)

Chapter 10: Complexity Value Stream Mapping and Complexity Analysis

241

(12)

Product/service family grid

242

(1)

Complexity Value Stream Map (CVSM)

243

(2)

Process Cycle Efficiency (PCE)

245

(1)

The Complexity Equation

245

(1)

Complexity matrix

246

(1)

PCE destruction calculations (for a Complexity Matrix)

247

(1)

Substructure analysis

248

(2)

"What-if' analyses with Complexity Matrix data

250

(3)

Chapter 11: Selecting and Testing Solutions

253

(24)

Sources of solution ideas

254

(1)

Benchmarking

254

(1)

Tips on solution selection

255

(1)

Developing and using evaluation criteria

256

(2)

Solution selection matrix

258

(3)

Pairwise ranking

261

(3)

Cost evaluation

264

(1)

Impact/effort matrix

264

(1)

Pugh matrix

265

(4)

Other evaluation techniques

269

(1)

Controls assessment matrix

269

(1)

Failure Modes and Effects Analysis (FMEA)

270

(3)

Pilot testing

273

(4)

Index

277

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The Lean Six Sigma Pocket Toolbook: A Quick Reference Guide to Nearly 100 Tools for Improving Quality and Speed

Summary

Author Biography

Table of Contents

Supplemental Materials