Leaning_Into_Six_Sigma

LeaningintoSixSigmaWarning:Readingthisbookcouldresultineffectivechangeoccurringinyourorganization.WheatFM.qxd1/30/200312:11PMPageiThispageintentionallyleftblank.LeaningintoSixSigmaAParableoftheJourneytoSixSigmaandaLeanEnterpriseBarbaraWheatChuckMillsMikeCarnellMcGraw-HillNewYorkChicagoSanFranciscoLisbonLondonMadridMexicoCityMilanNewDelhiSanJuanSeoulSingaporeSydneyTorontoWheatFM.qxd1/30/200312:11PMPageiiiCopyright©2003byTheMcGraw-HillCompanies,Inc.Allrightsreserved.ManufacturedintheUnitedStatesofAmerica.ExceptaspermittedundertheUnitedStatesCopyrightActof1976,nopartofthispublicationmaybereproducedordistributedinanyformorbyanymeans,orstoredinadatabaseorretrievalsystem,withoutthepriorwrittenpermissionofthepublisher.0-07-142894-1ThematerialinthiseBookalsoappearsintheprintversionofthistitle:0-07-141432-0Alltrademarksaretrademarksoftheirrespectiveowners.Ratherthanputatrademarksymbolaftereveryoccurrenceofatrademarkedname,weusenamesinaneditorialfash-iononly,andtothebenefitofthetrademarkowner,withnointentionofinfringementofthetrademark.Wheresuchdesignationsappearinthisbook,theyhavebeenprintedwithinitialcaps.McGraw-HilleBooksareavailableatspecialquantitydiscountstouseaspremiumsandsalespromotions,orforuseincorporatetrainingprograms.Formoreinformation,pleasecontactGeorgeHoare,SpecialSales,[e-mail][phone].TERMSOFUSEThisisacopyrightedworkandTheMcGraw-HillCompanies,Inc.(“McGraw-Hill”)anditslicensorsreserveallrightsinandtothework.Useofthisworkissubjecttotheseterms.ExceptaspermittedundertheCopyrightActof1976andtherighttostoreandretrieveonecopyofthework,youmaynotdecompile,disassemble,reverseengineer,reproduce,mod-ify,createderivativeworksbasedupon,transmit,distribute,disseminate,sell,publishorsublicensetheworkoranypartofitwithoutMcGraw-Hill’spriorconsent.Youmayusetheworkforyourownnoncommercialandpersonaluse;anyotheruseoftheworkisstrict-lyprohibited.Yourrighttousetheworkmaybeterminatedifyoufailtocomplywiththeseterms.THEWORKISPROVIDED“ASIS”.McGRAW-HILLANDITSLICENSORSMAKENOGUARANTEESORWARRANTIESASTOTHEACCURACY,ADEQUACYORCOMPLETENESSOFORRESULTSTOBEOBTAINEDFROMUSINGTHEWORK,INCLUDINGANYINFORMATIONTHATCANBEACCESSEDTHROUGHTHEWORKVIAHYPERLINKOROTHERWISE,ANDEXPRESSLYDISCLAIMANYWARRANTY,EXPRESSORIMPLIED,INCLUDINGBUTNOTLIMITEDTOIMPLIEDWARRANTIESOFMERCHANTABILITYORFITNESSFORAPARTICU-LARPURPOSE.McGraw-Hillanditslicensorsdonotwarrantorguaranteethatthefunc-tionscontainedintheworkwillmeetyourrequirementsorthatitsoperationwillbeunin-terruptedorerrorfree.NeitherMcGraw-Hillnoritslicensorsshallbeliabletoyouorany-oneelseforanyinaccuracy,errororomission,regardlessofcause,intheworkorforanydamagesresultingtherefrom.McGraw-Hillhasnoresponsibilityforthecontentofanyinformationaccessedthroughthework.UndernocircumstancesshallMcGraw-Hilland/oritslicensorsbeliableforanyindirect,incidental,special,punitive,consequentialorsimilardamagesthatresultfromtheuseoforinabilitytousethework,evenifanyofthemhasbeenadvisedofthepossibilityofsuchdamages.Thislimitationofliabilityshallapplytoanyclaimorcausewhatsoeverwhethersuchclaimorcausearisesincontract,tortorotherwise.DOI:10.1036/0071428941ebook_copyright7x9.qxd7/23/0311:05AMPage1ForewordviiIntroductionix1.SG,Inc.12.FirstImpressionsofthePlant43.WorkplaceOrganizationandtheFiveS’s134.TheResultsofFiveSImplementation215.SixSigmaStrategyforSid246.DefiningSixSigma307.ImplementingSixSigma338.TheCrow’sNest379.ANewCommitment4610.Lean:ListeningtotheProcess5011.FullCircle:LeantoSixSigmatoLeantoSixSigma5812.GettingOrganizedtoGetMeOut74Index81vContentsWheatFM.qxd1/30/200312:11PMPagevFormoreinformationaboutthistitle,clickhere.Copyright2003byTheMcGraw-HillCompanies,Inc.ClickHereforTermsofUse.Thispageintentionallyleftblank.TheSixSigmaconceptandTotalCycleTime(LeanEnterprise)weretwoofthekeyinitiativesundertakenbyMotorolabackinthemid-1980sthatIwasfortunateenoughtobeapartof.Thiscontinuousimprovementmethodologyworks,asevidencedbythefactthatmanycompaniesandqualityconsultantsaredeployingitcorrectly.EventheworldwideorganizationoftheAmericanSocietyforQualitywillbeestablishinganewcertificationexamforSixSigmaBlackBelts,whichtrulydemonstrateshowinstitutionalizedtheSixSigmaprocesshasbecome.Thisisthetypeofbookyouwanteverycompanyemployee,especiallyexecutiveleadersandmiddlemanagers,toreadbeforeyoustartyourLean/SixSigmadeployment.Everyoneeffectschangeinanorganizationandcanrelatetothevariouscharactersandtheirrolesinthisbook.Theauthorshavedoneanexcellentjobexplaininginanon-tech-nicalwaytheSixSigmaproblem-solvingmethodology,MAIC(Measure,Analyze,Improve,andControl),andwhyitiscriticalthatitbelinkedtotheFiveS’sofLeanEnterprise.Thismoderndayfable,whichcanbereadonyournextshortflight,depictsthe“typicalcompany”lookingforasolutiontochronicqualityissuesandamonth-enddeliverybottleneck,patchedupwithsignificantovertimeandresultinginpoorfinancials.viiForewordWheatFM.qxd1/30/200312:11PMPageviiCopyright2003byTheMcGraw-HillCompanies,Inc.ClickHereforTermsofUse.Samisinvitedtovisittheplantownertohelphimmakethedeci-siononwhichmachinetobuy.Samrunsin