Forrest W. Breyfogle III is the founder and President of Smarter Solutions, Inc., a company specializing in training
and consulting in Six Sigma methodologies. He is the author of Statistical Methods for Testing, Development, and
Manufacturing and Implementing Six Sigma and coauthor of Managing Six Sigma, all published by Wiley.
Review
"No other book covers--at an adequate technical level--as many topics important to Six Sigma. An indispensable
reference for the Six Sigma practitioner."
--Ramon V. Leon Associate Professor, Statistics Department of the University of Tennessee Associate editor,
Six Sigma Forum magazine
"Breyfogle's book should be valuable to every Six Sigma professional."
--Bill Scherkenback Director, Samsung Quality Team
"The seamless integration of statistical methodologies . . . helps organizations execute their strategic plans
and track both short- and longer-term strategic progress within their various departments and overall organizations."
--Donald C. Fisher, PhD Executive Director, MSQPC--The Quality Center
"Implementing Six Sigma provides the most up-to-date material on the topic, complete with a project infrastructure
roadmap and hundreds of real-life examples and exercises."
--Frank Shines Project Manager, Pilgrim Software
Publisher Web Site, March, 2003
Summary
This new and significantly revised edition of Implementing Six Sigma goes well beyond traditional Six Sigma
methodologies, introducing an enhanced roadmap-S4/IEE (Smarter Six Sigma Solutionssm/Integrated Enterprise Excellence).
This cutting-edge approach offers a solution to the common problem of sustaining Six Sigma activities and downplays
the traditional policy stating that Six Sigma projects must have a defined defect. A variety of plans, checklists,
metrics, and warnings of potential pitfalls provide thorough preparation for anyone implementing Six Sigma strategies.
With new coverage of Six Sigma infrastructure building, benchmarking, and real-world "lessons learned,"
this Second Edition is the best available tool for implementing these powerful, profit-building strategies.
Table of Contents
PREFACE.
PART I: S4/IEE DEPLOYMENT AND DEFINE PHASE FROM DMAIC.
1. Six Sigma Overview and S4/IEEE Implementation.
2. Voice of the Customer and the S4/IEEE Define Phase.
PART II: S4/IEE MEASURE PHASE FROM DMAIC.
3. Measurement and the S4/IEEE Measurement Phase.
4. Process Flow Charting/Process Mapping.
5. Basic Tools.
6. Probability.
7. Overview of Distributions and Statistical Processes.
8. Probability and Hazard Plotting.
9. Six Sigma Measurements.
10. Basic Control Charts.
11. Process Capability and Process Performance Metrics.
12. Measurement Systems Analysis.
13. Cause-and-Effect Matrix and Quality Function Deployment.
14. FMEA (Failure Mode and Effects Analysis).
PART III: S4/IEE ANALYZE PHASE FROM DMAIC (OR PASSIVE ANALYSIS PHASE).
15. Visualization of Data.
16. Confidence Intervals and Hypothesis Tests.
17. Inferences: Continuous Response.
18. Inference: Attribute (Pass/Fail) Response.
19. Comparison Tests: Continuous Response.
20. Comparison Tests: Attribute (Pass/Fail) Response.
21. Bootstrapping.
22. Variance Components.
23. Correlation and Simple Linear Regression.
24. Single-Factor (One-Way) Analysis of Variance (ANOVA) and Analysis of Means (ANOM).
25. Two-Factor (Two-Way) Analysis of Variance.
26. Multiple Regression, Logistic Regression, and Indicator Variables.
PART IV: S4/IEE IMPROVE PHASE FROM DMAIC (OR PROACTIVE TESTING PHASE).
27. Benefiting from Design of Experiments (DOE).
28. Understanding the Creation of Full and Fractional Factorial 2K DOEs.
29. Planning 2K DOEs.
30. Design and Analysis of 2K DOEs.
31. Other DOE Considerations.
32. Robust DOE.
33. Response Surface Methodology.
PART V: S4/IEE CONTROL PHASE FROM DMAIC AND APPLICATION EXAMPLES.
34. Short-Run and Target Control Charts.
35. Control Charting Alternatives.
36. Exponentially Weighted Moving Average (EWMA) and Engineering Process Control (EPC).
37. Pre-Control Charts.
38. Control, Plan, Poka-Yoke, Realistic Tolerancing, and Project Completion.
39. Reliability Testing/Assessment: Overview.
40. Reliability Testing/Assessment: Repairable System.
41. Reliability Testing/Assessment: Nonrepairable Devices.
42. Pass/Fall Functional Testing.
43. S4/IEEE Application Examples.
PART VI: S4/IEE LEAN AND THEORY OF CONSTRAINTS.
44. Lean and Its Integration with S4/IEEE .
45. Integrating of Theory of Constraints (TOC) in S4 /IEE.
PART VII: DFSS AND 21-STEP INTEGRATION OF THE TOOLS.
46. Manufacturing Applications and A 21-Step Integration of the Tools.
47. Service/Transactional Applications and A 21-Step Integration of the Tools.
48. DFSS Overview and Tools.
49. Product DFSS.
50. Process DFSS.
PART VIII: MANAGEMENT OF INFRASTRUCTURE AND TEAM EXECUTION.
51. Change Management.
52. Project Management and Financial Analysis.
53. Team Effectiveness.
54. Creativity.
55. Alignment of Management Initiatives and Strategies with S4/IEEE .
Appendix A. Supplemental Information.
Appendix B. Equations for the Distributions.
Appendix C. Mathematical Relationships.
Appendix D. DOE Supplement.
Appendix E. Reference Tables.
List of Symbols.
Glossary.
References.
Index.
