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

ISBN-10: 0071411836
ISBN-13: 9780071411837
Edition: 2003
Authors: Thomas Pyzdek
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Description: '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.

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Book details

List price: $55.00
Copyright year: 2003
Publisher: McGraw-Hill Education
Publication date: 4/11/2003
Binding: Paperback
Pages: 264
Size: 8.25" wide x 10.75" long x 0.75" tall
Weight: 1.298
Language: English

'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.

Thomas Pyzdek, Thomas Pyzdek earned his Bachelor's Degree in Liberal Arts from the University of Nebraska at Omaha and earned his Master's in Systems Engineering in 1982, and Management in 1995, from the University of Arizona. Pyzdek taught management statistics at the University of Arizona and for the American Society for Quality. He is a fellow of ASQ and is certified as both a Quality Engineer and a Reliability Engineer. Pyzdek has consulted for such large companies as Avon, McDonalds and Federal Mogul. He himself has launched two successful companies, Quality America, Inc, that specializes in statistical software, and Quality Publishing, Inc. which specializes in books and multimedia training materials. He also writes a regular column for Quality Digest Magazine. In 1995, Pyzdek was awarded the ASQ Edwards Medal for outstanding contributions to the practice of quality management. He also received the Hughes Engineering Master's Fellowship in 1980. He was a member of the Board of Examiners for the first Malcolm Baldridge National Quality Award and the Panel of Judges for the first Arizona Govenor's Award for Quality. Pyzdek is listed as an Outstanding Writer and Author by the INternational Who's Who in Quality.

List of Figures
List of Tables
List of Worksheets
Preface
Introduction
How to Use The Six Sigma Planner
Planning
Develop the Project Charter
Project Charter
The Project Charter Document
Conduct a Feasibility Analysis
Is This a Valid Project
Feasibility Analysis Study
The Project Plan
Project Metrics
Refining the Dollar Opportunity Estimates
How Will I Monitor Satisfaction with Project Success?
Identify Human Resources Need to Complete the Project
Identify Other Resources Needed to Complete the Project
Work Breakdown Structures
Creating the WBS
Integration and Test
Project Schedule Development
Activity Definition
Activity Dependencies
Estimating Activity Duration
Gantt Charts
Network Diagrams
Resource Availability
Calendars
Schedule Improvement
Estimating Project Duration Statistically
Calculating the Cost of a Schedule
Resource Leveling
Project Control Subplans
Risk Control Plan
Quality Plan
Cost Control Plan
Schedule Control Plan
Project Schedule Management
Scope Change Control Plan
Change Control System
Define
What Is the Current State?
What's Wrong with the Way Things are Now?
Quantify the Undesirable Effects
Tools and Techniques
Failure Mode and Effect Analysis (FMEA)
FMEA Process
Process Metrics
Other Key Factors and Metrics
How Does This Project Move the Organization Toward Its Strategic Goals and Objectives?
Measure
Measurement Reliability and Validity
Dimension Measurement Analysis
Attribute Measurement Analysis
Analyze
Quantify the Current Process
Catalog of Data Sources for This Process
Exploratory Data Analysis
Descriptive Data Analysis
Example of Using Worksheet
Quantify the Capability of the Current Process
Conduct a Process Audit
Prepare an Audit Report
Determine Sigma and DPMO Levels CTx's
Process Capability and Process Actual Sigma Levels Continuous CTx Characteristics
Measuring Process Capability for Variables Data
Measuring Actual Process Performance for Variables Data
Process Capability and Process Actual Sigma Levels for Attribute CTx Characteristics
Measuring Process Capability for Attributes Data
Measuring Actual Process Performance for Variables Data
Improve
Optimize the Process
Perform Designed Experiments
What Will the Future State Be?
What are the Best Practices in This Area?
Create a Future State Process Map
Six Sigma Project Activities Template
Presentation and Acceptance of Deliverables
Control
Control Failure Mode and Effect Analysis (FMEA)
Business Process Control Systems
How Will We Maintain the Gains Made?
A Tutorial on Project Selection and Management
Choosing the Right Projects
Customer Value Projects
Using QFD to Link Six Sigma Projects to Strategies
The Strategy Deployment Plan
Using Customer Demands to Design For Six Sigma
Structured Decision-Making
Shareholder Value Projects
Other Six Sigma Projects
Analyzing Project Candidates
Other Methods of Identifying Promising Projects
Using Pareto Analysis to Identify Six Sigma Candidates
Throughput-Based Project Selection
Multitasking and Project Scheduling
Critical Chain Project Portfolio Management
Summary and Preliminary Project Selection
Tracking Six Sigma Results
Financial Results Validation
Types of Savings
Lessons Learned: Capture and Replication
Appendices
Issues List
Risk Control Plan
Quality Plan
Cost Control Plan
Schedule Control Plan
Project Change Control Plan
Audit Report
Business Process Change Control Plan
Resource Calendars
Attribute Measurement Error Analysis
Calculating Yields
Normalized Yield and Sigma Level
Analytic Hierarchy Process (AHP) Using MS Excel
Additional Resources on Six Sigma Project Management
Figures
The Six Sigma Project Process Flow
Map of Six Sigma Project Flow
Six Sigma Project DMAIC Cycle Questions
Example of Project Validation Analysis
Example of Cost-Benefit Opportunity Calculations
WBS Creation Process Flowchart
Example of a WBS
Types of Activity Dependencies
Gantt Chart of Schedule
Gantt/Milestone Chart of Actual vs. Scheduled Performance
Example of Computer Gantt/Milestone Chart
Example of Network Diagram
Example of a Computer-Generated Network Diagram
Example of a Computer-Generated Human Resource Calendar
Computer Screen for Entering Task Duration Data
Results of Simulation for Example
Simulation Results: Probability of Meeting Due Date
Example of Cross-Functional Process Map
Define Gate Criteria
Measure Gate Criteria
Some EDA Techniques
Example of Combined DDA and EDA Analysis
Example of Evaluating a Hypothesis
Analyze Gate Criteria
Example of a Future State Process Map
Improve Gate Criteria
Control Gate Criteria
Strategy Deployment Plan
Strategy Deployment Matrix
QFD Relationship Weights and Symbols
Phase II Matrix: Differentiators
Phase III Matrix: Six Sigma Projects
Linkage Between Six Sigma Projects and Stakeholders
Customer Demand Model
Matrix of Categories for Pairwise Comparisons
Completed Top-Level Comparison Matrix
A Simple Process with a Constraint
Critical Chain Scheduling Illustration
Lithography Inspection Station Table, Stool, and Magnifying Glass
Attribute Gauge R&R Dialog Box and Data Layout
MINITAB "Agreement Within Appraiser"
Plot of "Agreement Within Appraiser"
MINITAB "Agreement of Appraiser with Standard"
Plot of "Agreement of Appraiser with Standard"
MINITAB "Appraiser Disagreement"
MINITAB "Agreement Between Appraisers"
MINITAB "Assessment vs. Standard Agreement Across All Appraisers"
Excel Spreadsheet for RTY
Excel Spreadsheet for Calculating Normalized Yield
Finding RTY Using Simulation Software
Tables
Instructions for Completing the Project Charter Statement Form
Strategies for Meeting the Project Goals
Tools Useful in Risk Assessment
Risk Planning vs. Impact and Likelihood of Threatening Events
Risk Response Planning Tools
FMEA Severity, Likelihood, Detectibility Rating Guidelines
FMEA Information
Phases in Process Optimization
Typical DMAIC Project Tasks and Responsibilities
Local and Global Importance Weights
Example of Using Global Weights in Assessing Alternatives
Dysfunctional Process Symptoms and Underlying Diseases
Illustration of the Pareto Priority Index (PPI)
Throughput Priority of CTx Projects That Affect the Constraint
Project Throughput Priority vs. Project Focus
Possible Information to Be Captured
A Typical View of Six Sigma Projects
Attribute Measurement Concepts
Methods of Evaluating Attribute Inspection
Results of Lithography Attribute Inspection Study
Inspector Accuracies
Repeatability and Pairwise Reproducibility for Both Days Combined
Stability Analysis
Calculations Used to Find RTY
Worksheets
Project Charter Statement
Project Validation Analysis
Six Sigma Project Evaluation
Six Sigma Project Evaluation Guidelines
Project Budget Development
Deliverables Metrics
Dollar Opportunity Estimate
Project Progress Satisfaction Metrics
Human Resources Assessment
Project Resource Planning
Project Work Breakdown Structure
List of Penalties for Missing Deadline
Major Milestones and Target Dates
Historical Research Summary
Constraint Analysis
Activity Dependenciesa
Activity Duration Estimates
List of Activities
Project Gantt/Milestone Chart Template
Project Gantt/Milestone Chart (Freehand Drawing Format)
Network Diagram for Project
Resource Availability Information
Schedule Improvement Evaluation
Best-Case, Expected, and Worst-Case Schedule Completion Dates
Statistical Analysis of Project Duration
Estimated Cost by Activity Duration
Cost-Optimization Spreadsheet Results
Cost-Optimization Graphical Analysis
Resource Leveling
Risk Event Classification
New Opportunities
Risk Response Plans
Quality Plan Items
Project Budget Reports and Reporting Frequency
Activity Status Management Report
Change Control Information
Controlled Documents List
Current Process Map
Narrative Description of Undesirable Effects
Undesirable Effects
FMEA Worksheet
CTQ Characteristics
CTS and CTC Characteristics
Other Key Factors and Metrics
Linkages to Enterprise Strategic Goals
Gauge R&R Results
Attribute Inspection System Results
Attribute Inspection Results by Inspector
Information Resource Catalog
DDA/EDA-Based Theories to Investigate Further
Process Audit Check Sheet
Actual CTx DPMO and Sigma Levels
Capability Levels of Performance
Rolled Throughput Yield Analysis
Optimum Levels of Performance
Optimum Rolled Throughput Yields
Benchmarking Step 1: Identify What Is to Be Benchmarked
Benchmarking Step 2: Identify Comparative Companies
Benchmarking Step 3: Determine Data Collection Methods
Benchmarking Step 4: Collect Data on Benchmark
Benchmarking Step 5: Determine the Current Performance Gap
Benchmarking Step 6: Identify Causes of the Performance Gap
Benchmarking Step 7: Estimate Future Performance Levels
Benchmarking Step 8: Establish Functional Goals and Gain Acceptance of Stakeholders
Alternative Future State Process Maps
Future State Improvement Estimates
Deliverables Acceptance Report
Control FMEA Worksheet
Additional Business Process Change Control Mechanisms
Project Assessment Summary
Issues List
Rolled Throughput Yields Worksheet

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