Lean Six Sigma International Standards and Global Guidelines

List of Figures..................................................................................................... xi

Preface................................................................................................................ xiii

Acknowledgments............................................................................................ xxi

About the Author

SECTION I    NEW GLOBAL STANDARDS YELLOW HIGHLIGHTS INDICATE SUBMITTED CHAPTERS -FINAL EDITS ON MY END

1        ISO 13053 International Standard for Six Sigma....................................

1.1        ISO 13053-1............................................................................................ 6

1.2        ISO 13053-2............................................................................................ 9

2        Lean Project Management........................................................................... 11

2.1        PMI Certifications.................................................................................. 18

2.2        PRINCE2 Certifications......................................................................... 19

2.3        The American Academy of Project Managers................................... 19

2.4        Self-Study............................................................................................... 20

3       Lean Government in the United States................................................ 23

3.1        International Government Communities............................................... 28

SECTION II    LEAN SIX SIGMA, OPERATIONAL EXCELLENCE, AND CONTINUOUS IMPROVEMENT

4        Core Knowledge............................................................................................ 35

4.1        Define, Measure, Analyze, Improve, and Control............................ 35

4.2        Plan–Do–Check–Act............................................................................. 36

4.3        DMAIC and PDCA.............................................................................. 37

4.4        Rapid Improvement or Kaizen Event Models.................................... 38

4.5        Discussion............................................................................................ 39

5        Lean Six Sigma Basics.................................................................................. 41

5.1        Discussion............................................................................................ 46

6        Analytical Problem-Solving Tools............................................................ 47

6.1        Flowcharting.......................................................................................... 48

6.2        Check Sheets........................................................................................ 49

6.3        Cause-and-Effect Diagram................................................................. 51

6.4        Histogram............................................................................................ 52

6.5        Pareto Chart......................................................................................... 54

6.6        Scatter Diagram................................................................................... 55

6.7        Control Charts...................................................................................... 59

6.8        Discussion............................................................................................ 62

7       DMAIC Basics............................................................................................ 63

7.1        Overview of DMAIC........................................................................... 64

7.2        Practice Exercises................................................................................. 67

8        Define............................................................................................................... 69

8.1        Process Mapping................................................................................. 70

8.2        Project Charter...................................................................................... 71

8.3        SWOT Analysis.................................................................................... 72

8.4        Critical to Quality.................................................................................. 73

8.5        SIPOC Diagram.................................................................................... 74

8.6        Quality Function Deployment........................................................... 75

8.7        DMAIC WBS......................................................................................... 76

8.8        Affinity Diagram................................................................................... 77

8.9        Kano Model.......................................................................................... 77

8.10    Discussion............................................................................................ 79

9        Measure.......................................................................................................... 81

9.1        Detailed Process Map......................................................................... 83

9.2        Benchmarking...................................................................................... 83

9.3        Scorecards.............................................................................................. 84

9.4        Failure Mode and Effects Analysis..................................................... 85

9.5        Sigma Calculations............................................................................... 87

9.6        Cp and Pp Indexes.............................................................................. 88

9.7        Measurement Systems Analysis.......................................................... 90

9.8        Data Collection Plan............................................................................ 91

9.9        Discussion............................................................................................ 92

10       Analyze....................................................................................................... 93

10.1    Correlation Analysis............................................................................. 95

10.2    The 5 Whys........................................................................................... 96

10.3    The Seven Tools for Process Improvement........................................ 96

10.4    Statistical Thinking.............................................................................. 97

10.5    Statistical Process Control.................................................................... 99

10.6    Stem-and-Leaf Diagram...................................................................... 102

10.7    Type I and Type II Errors................................................................. 103

Contents  ■  ix

10.8        Design of Experiment....................................................................... 103

10.9        Analysis of Variance......................................................................... 105

10.10    Discussion......................................................................................... 105

11       Improve.................................................................................................... 107

11.1    Project Plan......................................................................................... 111

11.2    Discussion........................................................................................... 113

12       Control...................................................................................................... 115

12.1    ROI Calculations.................................................................................. 116

12.2    Sustainability....................................................................................... 117

12.3    5S Plans............................................................................................... 119

12.4    Close-Out Activities........................................................................... 121

12.5    Discussion........................................................................................... 122

13       Summary of DMAIC........................................................................... 123

13.1    Discussion........................................................................................... 126

SECTION III    INTERNATIONAL IMPLEMENTATION

OF PROCESS IMPROVEMENT PROGRAMS

14       Additional Lean Six Sigma Tools....................................................... 129

14.1        Activity Network Diagram................................................................ 131

14.2        Box Plots........................................................................................... 132

14.3        Delphi Technique............................................................................. 133

14.4        Gantt Chart....................................................................................... 133

14.5        Matrix Diagram................................................................................. 133

14.6        Program Evaluation and Review Technique................................... 134

14.7        Prioritization Matrix.......................................................................... 134

14.8        Quality Function Deployment (also called QFD or House

of Quality)......................................................................................... 134

14.9        Stem-and-Leaf Plot........................................................................... 134

14.10    Discussion.......................................................................................... 135

15       Quick Start Guide................................................................................. 137

15.1    Discussion........................................................................................... 141

16       Leadership Challenge.......................................................................... 143

16.1    Discussion........................................................................................... 150

17. Change Management............................................................................. 151

18. Training Models Training Modules:  Using Instructional Systems Design for Lean Six Sigma Training

1.1.1      Analysis.................................................................................... 158

1.1.2      Design....................................................................................... 158

1.1.3      Development............................................................................ 158

1.1.4      Implementation........................................................................ 159

1.1.5      Evaluation................................................................................ 159

SECTION IV

LEAN SIX SIGMA APPLICATIONS

19.   Lean Six Sigma in Healthcare – Medical Facilities...................... 177

20.  Lean Six Sigma in the Medical Device Industry

21.   Lean Six Sigma and Artificial Intelligence

22.  Lean Six Sigma in Innovation and Design

SECTION V    INTERNATIONAL LEAN SIX SIGMA AREAS

OF COMPETENCY AND RESOURCE MATERIALS

·       Appendix One:  A Brief History of Lean Six Sigma

·       Appendix Two:  Pandemic Proofing the Future with Lean Six Sigma

·       Appendix Three:  Lean Six Sigma Competency Models

a.      Lean Six Sigma Green Belt

b.     Lean Six Sigma Black Belt

c.      Lean Six Sigma Master Black Belt

REFERENCE MATERIALS

Lean Six Sigma Body of Knowledge (Outline)

Lean Six Sigma Body of Knowledge (Narrative)

Biography

Terra Vanzant Stern, PhD, PMP, SPHR/GPHR is a Six Sigma Master Black Belt and technical writer. Her publications include books, white papers, and articles in the areas of leadership development, ethics, critical thinking, project management, and Lean Six Sigma. Dr. Vanzant Stern is the CEO of Simple, Smart Decision-Making, Inc. dba, SSD Global Solutions (SSD) and the inventor of Leaner Six Sigma (LrSS)™. LrSS™ is a methodology used to simplify the popular process improvement theory, Lean Six Sigma. SSD is a federal government contractor who is also a preferred vendor by the State of Colorado. SSD’s client list includes recognized names such as Southern California Edison, Tennessee Valley Authority, Fidelity Insurance, and Blue Cross/Blue Shield. SSD has an international presence working in countries such as Cameroon Africa. Dr. Vanzant Stern served as the Chair of the ASQ Lean Enterprise Division as well as ASQ Denver Section. Prior board positions have also included the Director, Strategic Planning, for the Colorado Human Resource Association (CHRA) and the Ethics Committee for the State of Colorado Office of Economic Development. She currently is on the board of the Colorado Lean Network.