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aSQ Quality Press

Milwaukee, Wisconsin

Second Edition

Roderick A. . Munro, Govindarajan Ramu,

and Daniel J. . Zrymiak American Society for Quality, Quality Press, Milwaukee 53203

© 2015 by ASQ

All rights reserved. Published 2015

Printed in the United States of America

21 20 19 18 17 16 15 5 4 3 2 1

Library of Congress Cataloging-in-Publication Data

Munro, Roderick A.

The c ertified six sigma green belt handbook / Roderick A. Munro, Govindarajan Ramu, and D aniel J. Zrymiak. - Second edition. pag es cm Revi sed edition of: The certified six sigma green belt handbook / Roderick A. Munro . . . [et al.]. c2008. Inc ludes bibliographical references and index. ISB

N 978-0-87389-891-1 (hard cover : alk. paper)

1. Si x sigma (Quality control standard) - Handbooks, manuals, etc. 2. Pr oduction man agement - Handbooks, manuals, etc. 3. Qu ality control - Statistical methods - Han dbooks, manuals, etc. I. Ra mu, Govindarajan. II. Z rymiak, Daniel J. III . Title. TS156 .C4235 2015 65

8.5 - dc23

2014

046292

ISBN 978-0-87389-891-1

No part of this book may be reproduced in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher.

Publisher: Lynelle Korte

Acquisitions Editor:

Mat t T. Meinholz

Managing Editor:

Pau l Daniel O'Mara

Production Administrator:

Ran dall Benson ASQ Mission: The American Society for Quality advances individual, organizational, and community excellence worldwide through learning, quality improvement, and knowledge exchange. Attention Bookstores, Wholesalers, Schools, and Corporations: ASQ Quality Press books, video, audio, and software are available at quantity discounts with bulk purchases for business, educational, or instructional use. For information, please contact ASQ Quality Press at 800-248-1946, or write to ASQ Quality Press, P.O. Box 3005, Milwaukee, WI 53201-3005. To place orders or to request ASQ membership information, call 800-248-1946. Visit our website at http://www.asq.org/quality-press.

Printed on acid-free paper

Michael J. cleary

Founder of PQ Systems, Inc.

Born June 3, 1939

Died suddenly on September 10, 2014

Dr. Cleary, a noted authority in the field of quality management and a charter member of the Education Division of the American Society for Quality Control (now ASQ), founded PQ Systems, Inc., in 1984, with headquarters in Dayton, Ohio, later opening PQ Systems Europe Ltd., with sales in continental Europe and the Middle East, and PQ Systems Pty Ltd. in Frankston, Australia, serving the Pacific Rim. The company's products help organizations demonstrate proof of the qua lity of their products and services using statistical methods and problem-solving tools. PQ Systems was named among the top 25 best places to work in Dayton in 2014. Cleary played a principal role in developing the Transformation of Ameri- can Industry national training project, as well as the Total Quality Transforma- tion training system. He served on the planning committee for the U.S.-Japanese Business Conference in Tokyo, and presented papers on statistical process control and the applications of quality management principles to a variety of audiences in Korea, China, France, Great Britain, Australia, Singapore, and Japan. He was the author of A Data Analysis Handbook: Using the SPSS System, as well as coeditor of Practical Tools for Continuous Improvement, volumes 1 and 2. As a professor of management science at Wright State University from 1971-

1996, Cleary was awarded the Business College Associates Alumni Teaching

Award. His 25-year professorship in management science enabled Cleary to con duct extensive research and garner valuable experience in expanding quality management methods. He was a leader in bringing quality management into the curriculum of the College of Business, and published articles and papers on issues related to quality management, statistical applications, and decision sciences in a variety of academic and professional journals. Cleary is survived by his wife of 50 years, Barbara A. Cleary, PhD, and their four sons: Sean (Katherine St. John), Timothy (Laura Jackson), Matthew (Liz Han sen), and Dennis (Karina Johansen), grandsons Michael Wyatt Cleary, Har mon Hemp- stead Cleary, Daniel St. John Cleary, and Victor Thomas Cleary, granddaugh- ter Johanna Sol Cleary, sister Joan Buckman, brother-in-law John Rathman, and nieces and nephews. vi Dedication xvi list of Figures and Tables Table 1.1 Some approaches to quality over the years. ........................... 5 Figu re 1.1 Exam ple of a process flowchart. ..................................... 16 Figu re 1.2 Rela tionships between systems, processes, subprocesses, and steps. ..... 17 Figu re 1.3

A feedb

ack loop. .................................................. 17 Figu re 1.4 Cate gories of inputs to a process step. ................................ 18 Figu re 1.5 Trad itional quality cost curves. ...................................... 24 Figu re 1.6 Mode rn quality cost curves. ........................................ 25 Tabl e 1.2

Risk a

nalysis table. ................................................ 27 Figu re 1.7

A form

at for SWOT analysis. ........................................ 27 Figu re 2.1

TPS ho

use. ........................................................ 32 Figu re 2.2

7S ada

ptation (Hirano). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Figu re 2.3

A sea of i

nventory often hides unresolved problems. ................... 42 Figu re 2.4 C-sh aped manufacturing cell. ....................................... 43 Figu re 2.5 Comm on symbols used in value stream mapping. ..................... 46 Figu re 2.6 Valu e stream map example. ......................................... 47 Tabl e 3.1 Desi gn objectives and outputs traceability matrix. ..................... 54 Figu re 3.1 Simp le risk matrix. ................................................ 57 Figu re 3.2 Samp le DFMEA headers. ........................................... 59 Figu re 3.3 Samp le PFMEA headers. ........................................... 60 Figu re 3.4

FMEA f

lowchart. .................................................. 61 Figu re 3.5

FMEA f

lowchart in line with common FMEA form. .................... 62 Tabl e 3.2 Step s in performing a design or process FMEA. ....................... 63 Tabl e 3.3 Poss ible severity evaluation criteria. ................................. 65 Tabl e 3.4 Poss ible occurrence evaluation criteria. ............................... 65 Tabl e 3.5 Poss ible detection evaluation criteria. ................................ 65 Figu re 3.6 Exam ple of RPN calculations. ....................................... 66 Figu re 3.7 Exam ple of FMEA reporting and RPN chart. .......................... 68 Figu re 3.8

A typi

cal risk action plan Gantt chart. ................................ 68 Figu re 3.9

A typi

cal top-level management review report for FMEA progress. ...... 69 Figu re 3.10

An exa

mple of a partially filled-in FMEA. ............................ 70 Figu re 3.11

This e

xample of a tree diagram is a fault tree (used to study defects and failures). ..................................................... 71 xvii Figure 3.12 Common types of FMEA. ........................................... 71 Fi gure 4.1 Pro cess diagram/model. ........................................... 77 Ta ble 4.1 Tip s for benchmarking. ............................................ 80 Fi gure 4.2 Bas ic SIPOC diagram. .............................................. 82 Fi gure 5.1 Exa mple of a QFD matrix for an animal trap. .......................... 89 Fi gure 5.2 Map t o the entries of the QFD matrix illustrated in Figure 5.1. ........... 90 Fi gure 5.3 Seq uence of QFD matrices for product, part, and process planning. ...... 90 Fi gure 5.4 Exa mple of a completed QFD matrix. ................................ 92 Fi gure 5.5 QFD s tage flow and relationships. ................................... 93 Fi gure 5.6 QFD i nput-output requirements matrix. ............................. 93 Ta ble 5.1 QFD v alue characteristics. .......................................... 94 Fi gure 6.1 Ris k assessment assignment matrix. ................................. 10 0

Figure 7.1

Exa mple of an activity network diagram. ............................. 103 F igure 7.2 Exa mple of an affinity diagram. ..................................... 104 F igure 7.3 Exa mple of a cause-and-effect diagram. .............................. 10 8

Figure 7.4

Exa mple of a check sheet. ........................................... 109 F igure 7.5 Hig h-level flowchart for an order-filling process. ...................... 110 F igure 7.6 Det ailed flowchart for the order-filling process. ....................... 111 Fi gure 7.7 Exa

mple of force-field analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

112
F igure 7.8 Gan tt chart example. ............................................... 112 F igure 7.9 Gra phical representation of question responses. ....................... 114 F igure 7.10 Exa mple interrelationship digraph. .................................. 116 F igure 7.11 Exa mple matrix diagram. ........................................... 117 F igure 7.12 PDC

A cycle.

...................................................... 118 F igure 7.13 Pri oritization matrix example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
F igure 7.14 Exa mple process decision program chart (PDPC). ..................... 121 F igure 7.15 PER

T/critical path chart example.

................................... 122 F igure 7.16 SIP

OC diagram with requirements capture.

.......................... 124 F igure 7.17 Thi s example of a tree diagram is a fault tree (used to study defects and failures). ..................................................... 125 T able 9.1 Com mon negative team dynamics and potential countermeasures. ...... 136 F igure 9.1 Typ ical large Six Sigma organization. ................................ 140 F igure 9.2 Typ ical small Six Sigma organization. ................................ 141 T able 9.2 Typ ical Six Sigma roles. ............................................ 141 F igure 9.3 Mul tivoting ranked approach example. .............................. 151 F igure 9.4 Mul tivoting weighted approach example. ............................. 152 F igure 10.1 Sym bols commonly used in flowcharts and process maps. .............. 155 F igure 10.2 Bas ic flowchart for warranty product replacement. .................... 156 Fquotesdbs_dbs11.pdfusesText_17

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