The Six Sigma Way Team Fieldbook: An Implementation Guide for Process Improvement Teams

Home >
Browse >
The Six Sigma Way Team Fieldbook: An Implementation Guide for Process Improvement Teams

The Six Sigma Way Team Fieldbook: An Implementation Guide for Process Improvement Teams

Authors: Peter Pande, Robert Neuman and Roland Cavanagh

Published: December 2001

eISBN: 9780071431491 0071431497 | ISBN: 9780071373142

Contents

Preface

Part One. What a Six Sigma Project Team Needs to Know Before It Gets Started

1. The Six Sigma System

What Is Six Sigma?

System Alignment: Tracking the Xs and Ys

Six Ingredients of Six Sigma

Moving Forward

Eyes on the Prize: Using Six Sigma Teams as a Learning Tool

2. Three Ways to Six Sigma

1. Process Improvement: Finding Targeted Solutions

2. Process Design/Redesign

3. Process Management for Six Sigma Leadership

Using All Three Strategies

Choosing a Six Sigma Approach

3. Organizing for Six Sigma

Role 1: The Leadership Group or Council

Role 2: Project Sponsors and Champions

Role 3: The Implementation Leader

Role 4: The Six Sigma Coach (Master Black Belt)

Role 5: The Team or Project Leader (Black Belt)

Role 6: Team Members

Role 7: The Process Owner

Black Belts, Master Black Belts, and Green Belts

Conclusion

4. Selecting Winning Six Sigma Projects

Start Simply When Learning a New Language

Three Project Selection Essentials

Project Selection Process

Do’s and Don’ts When Selecting Projects

5. A Basic Toolkit for Team Leaders

A. Understanding Team Dynamics: The Evolution of Six Sigma Teams

B. Facilitation Skills

Meeting Tips for Six Sigma Teams

Basic Discussion Skills

C. Data Collection: The Right Tool for the Right Time

D. Organizational Communication

Getting Started

First Team Meeting Agenda

The Path Forward

Part Two. Leading a Six Sigma Project Team Through DMAIC

The Define Stage

6. Define the Opportunity

Define Step 1: Update and Expand Your DMAIC Project Charter

Charter Do’s and Don’ts

Define Step 2: Identify Customer Requirements

Defining Requirements Do’s and Don’ts

Define Step 3: Identifying and Documenting the Process

SIPOC Do’s and Don’ts

Finishing Your Define Work

7. Power Tools for “Define”

DMAIC Project Charter Worksheet

Problem/Opportunity Statement Worksheet

DMAIC Project Plan Worksheet

Gantt Chart

Project Stakeholder Analysis Worksheet

Service or Output Requirement Instructions

Requirement Statement Worksheet

Kano Analysis Instructions

SIPOC Analysis and Map

Define Completion Checklist

Define Tollgate Preparation Worksheet

The QFD Cycle

8. Coming Together as a Team

Tips for the Forming Stage

Troubleshooting and Problem Prevention for Define

The Measure Stage

9. Measuring Process Performance

Basic Measurement Concepts

Two Components of Measure

Getting Ready for Analyze

10. Power Tools for “Measure”

Measurement Planning Worksheet

CTQ Tree

Stratification Factors

Measurement Assessment Tree

Operational Definition Worksheet

Process and Population Sampling

Daily and Weekly Sampling Charts

Checksheet Development Instructions

Sigma Calculation Worksheet

Proportion Defective and Yield Calculation Instructions

Cost of Poor Quality (COPQ) Calculations

Measure Checklist

Tollgate Preparation Worksheet

Tracking Long-Term Variation and Process Shifts

11. Guiding the Six Sigma Team in the Measure Stage

The Anatomy of Team Storming

Troubleshooting and Problem Prevention for Measure

Measure Do’s and Don’ts

The Analyze Stage

12. Analyzing Data and Investigating Causes

Becoming a Defect Detective

Data Analysis: Exploring

Data Analysis: Generating Hypotheses About Causes

Data Analysis: Verifying Causes

Process Analysis: Exploring

Process Analysis: Generating Hypotheses About Causes

Process Analysis: Verifying Causes

Advanced Analytical Tools

Getting Ready for Improve

13. Power Tools for “Analyze”

Pareto Analysis and Chart

Run Chart, Trend Chart, Time Plot

Histogram or Frequency Plot

Cause-and-Effect Analysis (Fishbone or Ishikawa Diagram)

Relations Diagram

Scatter Plot or Correlation Diagram

Stratified Charts

Process Manipulation/Experimentation Worksheet

Detailed Process Maps or Flowcharts

Cross-Functional or Deployment Process Map

Process Value and Time Analysis

Analyze Checklist

Analyze Tollgate Preparation Worksheet

Hypothesis Testing: Determining Statistical Significance

Regression and Correlation Analysis

Exploring Complex Relationships: Using Design of Experiments to Screen, Verify, or Quantify Causes

14. Normal Data and Team Norms

1. Draw Attention to Team Progress

2. Build Momentum by Fixing “Low-Hanging Fruit”

3. Revisit and Update Team Ground Rules

4. Pay More Attention to How the Team Works Together

Troubleshooting and Problem Prevention for Analyze

The Improve Stage

15. Improving the Process

Steps to Workable, Effective Solutions

Step 1. Generate Creative Solution Ideas: Learning to be Practically Impossible

Step 2: Cook the Raw Ideas: Synthesizing Solution Ideas

Step 3. Select a Solution

Step 4. Pilot Test

Step 5. Implement Full-Scale

Getting Ready for Control

16. Power Tools for “Improve”

Advanced Creativity Techniques

Assumption Busting

The Practicality Scale

Tree Diagram for Solution Development

Impact/Effort Matrix

Criteria or Decision Matrix

Force Field Analysis

Pilot Planning Checklist

Pilot Testing Debrief

Improve Checklist

Improve Tollgate Preparation Worksheet

FMEA (Failure Modes and Effects Analysis)

Design of Experiments (DOE)

17. “At Last We’re a Team!”

Building Stakeholder Support (The Politics of Successful Change)

If a Tree Falls in the Woods ...

Improving the Team’s Own Processes

Troubleshooting and Problem Prevention for Improve

Improve Do’s and Don’ts

The Control Stage

18. Control and Process Management

Part 1. Discipline

Part 2. Documenting the Improvement

Part 3. Keeping Score: Establishing Ongoing Process Measures

Part 4. Going the Next Step: Building a Process Management Plan

Ending the Project

19. Power Tools for “Control”

Process Documentation Checklist

Control Charts

Process Management Chart

Response Plan Worksheet

Process Dashboards

Control Checklist

Control Tollgate Preparation Worksheet

20. Guiding Your Team in the Control Stage

Troubleshooting and Problem Prevention for Control

Control Do’s and Don’ts

21. Six Sigma Process Design/Redesign

Think Before You Act

Implementing a Design/Redesign Project

Before You Begin: Have a Vision

Step 1: Define the Design/Redesign Goal, Scope, and Requirements

Step 2: Measure to Establish Baseline Performance

Step 3: Analyze the Critical Elements

Step 4: Improve: Designing and Implementing the New Process

Step 5: Control the New Process

Other Elements of the Design/Redesign Path

Index