Transcription
THE CERTIFIED SIX SIGMABLACK BELT HANDBOOKSECOND EDITIONT. M. KubiakDonald W. BenbowASQ Quality PressMilwaukee, Wisconsin
Table of Contentslist of Figures and TablesPreface to the Second EditionPreface to the First EditionAcknowledgmentsxvxxiiixxvxxviiPart I Enterprise-Wide Deployment1Chapter 1 Enterprise-Wide ViewHistory of Continuous ImprovementValue and Foundations of Six SigmaValue and Foundations of LeanIntegration of Lean and Six SigmaBusiness Processes and SystemsSix Sigma and Lean Applications22678910Chapter 2 LeadershipEnterprise Leadership ResponsibilitiesOrganizational RoadblocksChange ManagementSix Sigma Projects and Kaizen EventsSix Sigma Roles and Responsibilities141414151617Part II Organizational Process Management and Measures21Chapter 3 Impact on StakeholdersImpact on Stakeholders2222Chapter 4 Critical to x (CTx) RequirementsCritical to x (CTx) Requirements2424Chapter 5 BenchmarkingBenchmarking2626Chapter 6 Business Performance MeasuresBusiness Performance Measures2828VII
viii Table of ContentsChapter 7 Financial MeasuresFinancial Measures3232Part III Team Management37Chapter 8 Team FormationTeam Types and ConstraintsTeam RolesTeam Member SelectionLaunching Teams3838394041Chapter 9 Team FacilitationTeam MotivationTeam StagesTeam Communication42424344Chapter 10 Team DynamicsTeam Dynamics4646Chapter 11 Time Management for TeamsTime Management for Teams4949Chapter 12 Team Decision-Making ToolsTeam Decision-Making Tools5050Chapter 13 Management and Planning ToolsManagement and Planning Tools5252Chapter 14 Team Performance Evaluation and RewardTeam Performance Evaluation and Reward5858Part IV Define61Chapter 15 Voice of the CustomerCustomer IdentificationCustomer FeedbackCustomer Requirements62626364Chapter 16 Project CharterProblem StatementProject ScopeGoals and ObjectivesProject Performance Measures7171727374Chapter 17 Project TrackingProject Tracking7575
TABLE OF CONTENTSixPart V Measure79Chapter 18 Process CharacteristicsInput and Output VariablesProcess Flow Metrics.Process Analysis Tools80808183Chapter 19 Data CollectionTypes of DataMeasurement ScalesSampling MethodsCollecting Data9090919293Chapter 20 Measurement SystemsMeasurement MethodsMeasurement Systems AnalysisMeasurement Systems in the EnterpriseMetrology959597118119Chapter 21 Basic StatisticsBasic TermsCentral Limit TheoremDescriptive StatisticsGraphical MethodsValid Statistical Conclusions122122123126129137Chapter 22 ProbabilityBasic ConceptsCommonly Used DistributionsOther Distributions138138148158Chapter 23 Process CapabilityProcess Capability IndicesProcess Performance IndicesShort-Term and Long-Term CapabilityProcess Capability for Non-Normal DataProcess Capability for Attributes DataProcess Capability StudiesProcess Performance vs. Specification167167171173174175176178Part VI Analyze183Chapter 24 Measuring and Modeling Relationships between Variables.Correlation CoefficientRegressionMultivariate Tools . . . :Multi-Vari StudiesAttributes Data Analysis184184188197208217
Table of ContentsChapter 25 Hypothesis TestingTerminologyStatistical vs. Practical SignificanceSample SizePoint and Interval EstimatesTests for Means, Variances, and ProportionsAnalysis of Variance (ANOVA)Goodness-of-Fit (Chi Square) TestsContingency TablesNon-Parametric Tests230230231231234244255259261264Chapter 26 Failure Mode and Effects Analysis (FMEA)Failure Mode and Effects Analysis (FMEA)278278Chapter 27 Additional Analysis MethodsGap AnalysisRoot Cause AnalysisWaste Analysis283283284290Part VII Improve293Chapter 28 Design of Experiments (DOE)TerminologyDesign PrinciplesPlanning ExperimentsOne-Factor ExperimentsTwo-Level Fractional Factorial ExperimentsFull Factorial Experiments294294297309311319325Chapter 29 Waste EliminationWaste Elimination332332Chapter 30 Cycle-Time ReductionCycle-Time Reduction337337Chapter 31 Kaizen and Kaizen BlitzKaizen and Kaizen Blitz342342Chapter 32 Theory of Constraints (TOOTheory of Constraints (TOC)'.344344Chapter 33 ImplementationImplementation347347Chapter 34 Risk Analysis and MitigationRisk Analysis and Mitigation351351
TABLE OF CONTENTSxiPart VIII Control357Chapter 35 Statistical Process Control (SPC)ObjectivesSelection of Variables. . Rational SubgroupingControl Chart SelectionControl Chart Analysis358358360360361389Chapter 36 Other Control ToolsTotal Productive Maintenance (TPM)Visual Factory400400401Chapter 37 Maintain ControlsMeasurement System Re-analysisControl Plan403403406Chapter 38 Sustain ImprovementsLessons LearnedTraining Plan DeploymentDocumentationOngoing Evaluation408408409410411Part IX Design for Six Sigma (DFSS) Frameworks andMethodologies413Chapter 39 Common DFSS MethodologiesDMADV (Define, Measure, Analyze, Design, and Validate)DMADOV (Define, Measure, Analyze, Design, Optimize, and Validate) . . .414414415Chapter 40 Design for X (DFX)Design for X (DFX)416416Chapter 41 Robust Design and ProcessRobust Design and Process418418Chapter 42 Special Design ToolsStrategicTactical424424426-.Part X Appendices431Appendix 1 ASQ Code of Ethics (May 2005)433Appendix 2A ASQ Six Sigma Black Belt Certification Bodyof Knowledge (2007)434Appendix 2B ASQ Six Sigma Black Belt Certification Bodyof Knowledge (2001)447
xiiTable of ContentsAppendix 3 Control Chart Combinations for Measurement Data460Appendix 4 Control Chart Constants462Appendix 5 Constants for A7, B7, and B8465Appendix 6 Factors for Estimating ox470Appendix 7 Control Charts Count Data471Appendix 8 Binomial Distribution Table472Appendix 9 Cumulative Binomial Distribution Table476Appendix 10 Poisson Distribution Table481Appendix 11 Cumulative Poisson Distribution Table489Appendix 12 Standard Normal Distribution Table496Appendix 13 Cumulative Standard Normal Distribution Table499Appendix 14 t Distribution Table502Appendix 15 Chi-Square Distribution Table504Appendix 16 F(0.99) Distribution Table507Appendix 17 F(0.975) Distribution Table511Appendix 18 F(0.95) Distribution Table515Appendix 19 F(0.90) Distribution Table519Appendix 20 F(0.10) Distribution Table523Appendix 21 F(0.05) Distribution Table527Appendix 22 F(0.025) Distribution Table531Appendix 23 F(0.01) Distribution Table535Appendix 24 Median Ranks Table539Appendix 25 Normal Scores Table543Appendix 26 Factors for One-Sided Tolerance Limits546Appendix 27 Factors for Two-Sided Tolerance Limits550Appendix 28 Equivalent Sigma Levels, Percent Defective, and PPM554Appendix 29 Critical Values for the Mann-Whitney Test Table (One-Tail,Alpha 0.05)Appendix 30 Critical Values for the Mann-Whitney Test Table (One-Tail,Alpha 0.01)556557
TABLE OF CONTENTSAppendix 31 Critical Values for the Mann-Whitney Test Table (Two-Tail,Alpha 0.025)xiii558Appendix 32 Critical Values for the Mann-Whitney Test Table (Two-Tail,Alpha 0.005)559Appendix 33 Critical Values for the Wilcoxon Signed-Rank Test560Appendix 34 Glossary of Six Sigma and Related Terms561Appendix 35 Glossary of Japanese Terms600BibliographyIndex603609CD-ROM ContentsSample Examination Questions for Parts I-IXCertified Six Sigma Black Belt—Simulated Exam
THE CERTIFIED SIX SIGMA BLACK BELT HANDBOOK SECOND EDITION T. M. Kubiak Donald W. Benbow ASQ Quality Press Milwaukee, Wisconsin. Table of Contents list of Figures and Tables xv Preface to the Second Edition xxiii Preface to the First Edition xxv
