Statistics for Six Sigma Made Easy

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Statistics for Six Sigma Made Easy

Statistics for Six Sigma Made Easy

Authors: Warren Brussee

Published: May 2004

eISBN: 9780071502023 0071502025 | ISBN: 9780071433853

Contents

Introduction

Part I: Overview of the Six Sigma Process and the DMAIC Roadmap

Chapter 1 Six Sigma Methodology and Management's Role in Implementation

Average and Variation

Sigma

Implementing Six Sigma

Chapter 2 DMAIC: The Basic Six Sigma Roadmap

Using DMAIC

Case Study: Using the DMAIC Process for Project Control and Review

Part II: Qualitative Six Sigma Tools

Chapter 3 Simplified QFD

Simplified QFD Instructions

Case Study: A Simplified QFD on a Test Cutting Machine

Traditional QFDs

Chapter 4 Simplified FMEA

Simplified FMEA Instructions

Case Study: A Potentially Life-Saving Simplified FMEA

Traditional FMEAs

Chapter 5 Cause-and-Effect Fishbone Diagram

Fishbone Diagram Instructions

Chapter 6 Simplified Process Flow Diagram

Simplified Process Flow Diagram Instructions

Chapter 7 Correlation Tests

Correlation Test Instructions

Case Study: Incorrect Cause

Part III: Foundations for Using Statistical Six Sigma Tools

Chapter 8 Getting Good Samples and Data

Hawthorne Effect

Case Study: Outcome Bias

Variables

Process Off-Center

Centering or Variation?

Process with Too Much Variation

Importance of Getting Good Samples and Data

Chapter 9 Simplified Gauge Verification

Maximum Gauge Error

Case Study: Gauge Error on Measuring Molds

Simplified Gauge Verification Instructions

Case Study: Gauge Differences Between Customer and Supplier

Gauge R&R

Chapter 10 Probability

Case Study: Application of Simple Probability

Uses of Probability

Case Study: Excessive Accident Rate

Case Study: Defects Primarily in One Quadrant

Chapter 11 Data Plots and Distributions

Case Study: Comparing Plots of Two Production Lines

Normal Data

Z Value

Case Study: Incur Great Costs Rather than Plotting

Plotting Data

Case Study: Not Testing a Graph for Reasonableness

Part IV: Six Sigma Tools to Test for Statistically Significant Change

Chapter 12 Testing for Statistically Significant Change Using Variables Data

Case Study: Obscene Scrap Call

Estimating a Population Average X and Sigma S

Case Study: Enforcing Minimum Sample Size

Using a Sample to Check for a Change Versus a Population

Checking for a Change Between Two Samples

Incidental Statistics Terminology Not Used in Above Tests

Chapter 13 Testing for Statistically Significant Change Using Proportional Data

Case Study: Testing if an Automatic Packer Damaged Product

Case Study: Isolating Bad Product!

Chapter 14 Testing for Statistically Significant Change Using Non-Normal Distributions

Case Study: Testing for Change on Non-Normal Data

Part V: Additional Six Sigma Tools

Chapter 15 Simplified Design of Experiments

Simplified DOE Steps

Case Study: Simplified DOE on a Test Tubing Cutter

Chapter 16 Simplified Control Charts

Traditional Control Charts

Simplified Control Charts

Case Study: Simplified Control Chart's Perceived Six Sigma

Case Study: Control Chart Vanquishes Losses

Control Charts for KPIVs

Part VI: Statistical Tools for Design for Six Sigma

Chapter 17 What Tolerance Is Really Required?

Case Study: Required Tolerances on Molds

Tolerance Stack-Up

RSS Tolerance Calculations

Case Study: Loosening Excessively Tight Tolerances

Chapter 18 Simplified Linear Transfer Functions

Case Study: Finding Grinding Issue Using Transfer Function

Part VII: Six Sigma Data and Quality Management Data

Chapter 19 Comparing Six Sigma Data with Quality Department Data

Appendices

Appendix A: The Six Sigma Statistical Tool Finder Matrix

Appendix B: Six Sigma Tool Check-Off List

Appendix C: Formulas Used in This Book

Appendix D: Tables Used in This Book

Appendix E: Glossary of Terms

A

B

C

D

E

F

G

I

L

M

N

P

R

S

T

V

Index