Simulation-based Lean Six-Sigma and Design

This is the first book to completely cover the whole body of knowledge of Six Sigma and Design for Six Sigma with Simulation Methods as outlined by the American Society for Quality. Both simulation and contemporary Six Sigma methods are explained in detail with practical examples that help understanding of the key features of the design methods. The systems approach to designing products and services as well as problem solving is integrated into the methods discussed.

BASEM EL-HAIK, PhD, is a Six Sigma and Design for Six Sigma consultant, author, and founder of Six Sigma Professionals, Inc., a firm providing Six Sigma and DFSS implementation, training, and consulting for industries ranging from financial services to high technology. Dr. El-Haik is a well-known author, consultant, and speaker on the subject. Throughout his career Dr. El-Haik trained, certified, coached, and mentored over 400 belts (Green Belts, Black Belts, and Master Black Belts) in DFSS and Six Sigma in both tracks: product and service (transactional).

RAID AL-AOMAR, PhD, is Assistant Professor of Industrial Engineering at Jordan University of Science and Technology (JUST). Dr. Al-Aomar has worked for several years as a consultant on Simulation and Lean Manufacturing at General Motors and Ford Motor Company in Detroit and as an adjunct faculty member at Wayne State University.

PREFACE

xi

PART I SIX-SIGMA FUNDAMENTALS

1

(70)

1 Six-Sigma Fundamentals

3

(18)

1.1 Introduction,

3

(2)

1.2 Quality and Six-Sigma Defined,

5

(2)

1.3 Introduction to Process Modeling,

7

(2)

1.4 Introduction to Business Process Management,

9

(2)

1.5 Measurement Systems Analysis,

11

(1)

1.6 Process Capability and Six-Sigma Process Performance,

12

(3)

1.7 Overview of Six-Sigma Improvement: DMAIC,

15

(3)

1.8 Six-Sigma Goes Upstream: Design for Six-Sigma,

18

(1)

1.9 Summary,

18

(3)

2 Lean Six-Sigma Fundamentals

21

(38)

2.1 Introduction,

21

(2)

2.2 Lean Six-Sigma Approach,

23

(3)

2.3 LSS-Enhanced DMAIC,

26

(4)

2.4 Lean Manufacturing,

30

(5)

2.5 Value Stream Mapping,

35

(4)

2.6 Lean Techniques,

39

(18)

2.7 Summary,

57

(2)

3 Design for Six-Sigma Fundamentals

59

(12)

3.1 Introduction,

59

(2)

3.2 Transaction-Based Design for Six-Sigma,

61

(2)

3.3 Service Design for Six-Sigma,

63

(2)

3.4 Service DFSS: The ICOV Process,

65

(3)

3.5 Service DFSS: The ICOV Process in Service Development,

68

(1)

3.6 Summary,

69

(2)

PART II SIMULATION FUNDAMENTALS

71

(118)

4 Basic Simulation Concepts

73

(26)

4.1 Introduction,

73

(1)

4.2 System Modeling,

74

(10)

4.3 Simulation Modeling,

84

(5)

4.4 The Role of Simulation,

89

(6)

4.5 Simulation Software,

95

(1)

4.6 Summary,

96

(3)

5 Discrete Event Simulation

99

(34)

5.1 Introduction,

99

(1)

5.2 System Modeling with DES,

100

(4)

5.3 Elements of Discrete Event Simulation,

104

(8)

5.4 DES Mechanisms,

112

(9)

5.5 Manual Simulation Example,

121

(5)

5.6 Computer DES Example,

126

(5)

5.7 Summary,

131

(2)

6 The Simulation Process

133

(34)

6.1 Introduction,

133

(1)

6.2 Categories of Simulation Studies,

134

(5)

6.3 Systematic Simulation Approach,

139

(5)

6.4 Steps in a Simulation Study,

144

(14)

6.5 Example: Applying Simulation Process to a Hospital Emergency Room,

158

(8)

6.6 Summary,

166

(1)

7 Simulation Analysis

167

(22)

7.1 Introduction,

167

(1)

7.2 Terminating Versus Steady-State Simulation,

168

(4)

7.3 Determination of Simulation Run Controls,

172

(9)

7.4 Variability in Simulation Outputs,

181

(4)

7.5 Simulation-Based Optimization,

185

(4)

PART III SIMULATION-BASED SIX-SIGMA AND DESIGN FOR SIX-SIGMA

189

(154)

8 Simulation-Based Six-Sigma Road Maps

191

(28)

8.1 Introduction,

191

(1)

8.2 Lean Six-Sigma Process Overview,

192

(2)

8.3 Simulation-Based Lean Six-Sigma Road Map,

194

(9)

8.4 Simulation-Based Design for a Six-Sigma Road Map,

203

(15)

8.5 Summary,

218

(1)

9 Simulation-Based Lean Six-Sigma Application

219

(48)

9.1 Introduction,

219

(2)

9.2 3S-LSS Integrated Approach,

221

(5)

9.3 3S-LSS Case Study,

226

(39)

9.4 Summary,

265

(2)

10 Simulation-Based Design for Six-Sigma Application

267

(40)

10.1 Introduction,

267

(2)

10.2 3S-DFSS Process,

269

(1)

10.3 3S-DFSS Case Study: Dental Clinic Redesign,

270

(36)

10.4 Summary,

306

(1)

11 Practical Guide to Successful Development of Simulation-Based Six-Sigma Projects

307

(36)

11.1 Introduction,

307

(1)

11.2 Characteristics of a 3S Application,

308

(7)

11.3 Ingredients for a Successful 3S Program,

315

(2)

11.4 Framework for Successful 3S Implementation,

317

(7)

11.5 3S Project Charter,

324

(2)

11.6 3S Software Tools,

326

(17)

APPENDIX A BASIC STATISTICS

343

(20)

APPENDIX B RANDOM NUMBERS

363

(4)

APPENDIX C AXIOMATIC DESIGN

367

(8)

APPENDIX D TAGUCHI'S QUALITY ENGINEERING

375

(6)

APPENDIX E PROCESS MAPPING

381

(6)

APPENDIX F VENDORS

387

(8)

REFERENCES AND FURTHER READING

395

(6)

INDEX

401

What is included with this book?

The New copy of this book will include any supplemental materials advertised. Please check the title of the book to determine if it should include any access cards, study guides, lab manuals, CDs, etc.

The Used, Rental and eBook copies of this book are not guaranteed to include any supplemental materials. Typically, only the book itself is included. This is true even if the title states it includes any access cards, study guides, lab manuals, CDs, etc.

FREE SHIPPING

Rent More, Save More! Use code: BBRENTAL

5% off 1 book, 7% off 2 books, 10% off 3+ books

Simulation-based Lean Six-Sigma and Design for Six-Sigma

Summary

Author Biography

Table of Contents

Supplemental Materials