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Implementing Lean Six Sigma throughout the Supply Chain : The Comprehensive and Transparent Case Study - Elizabeth A. Cudney

Implementing Lean Six Sigma throughout the Supply Chain

The Comprehensive and Transparent Case Study

Paperback Published: 14th October 2010
ISBN: 9781439828144
Number Of Pages: 280

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Explanations of theory, lists of rules, and discussions of procedure are the basis of learning the lean Six Sigma, however without a visceral understanding of the application of this powerful system in various circumstances the knowledge remains, at best, conjecture. Detailed examination of case studies that take real-world variables into account is the only way to truly master Lean Six Sigma.

Providing a comprehensive Lean Six Sigma case study from start to finish, Implementing Lean Six Sigma throughout the Supply Chain: The Comprehensive and Transparent Case Study employs the Define-Measure-Analyze-Improve-Control (DMAIC) process used in today's retail industry.

Going far beyond the brief overview found in current texts, this interactive case study presents all of the data used by a team as they implement Lean Six Sigma in a distribution center. It details their decision-making rational, thus allowing the reader to extrapolate and implement the same analyses and conclusions in their own settings.

An interactive CD accompanies the book and contains all of the numerous graphs, charts, tables, and data analyses provided in the text. It provides PowerPoint training slides and easily accessible data sets that correspond to the figures in the book, as well as a full Glossary and reference guide to commonly used Lean and Six Sigma terms.

Providing a clear link between all of the Lean Six Sigma tools and their application in a real-world setting, indispensible training tool gives the all-important, rubber-meets-the-road understanding needed to start you on your Lean Six Sigma journey.

Acknowledgmentsp. xi
Authorsp. xiii
Introductionp. 1
How To Use the CDp. 2
CD Instructionsp. 2
Lean Six Sigma Overviewp. 5
Case Study Introductionp. 11
Define Phasep. 15
Introductionp. 15
Midwest Logistics, Lean Six Sigma Core Teamp. 16
Develop Initial Documentsp. 19
Project Charterp. 20
Supplier-Input-Process-Output-Customer (SIPOC)p. 25
Identify Stakeholders and Develop Communication Planp. 28
Communications Strategy Listp. 32
Perform Initial VOC and Identify CTSp. 35
Select the Team and Launch the Projectp. 39
Midwest Logistics, Lean Six Sigma Team Additionsp. 40
Create Responsibility Matrix (RASIC)p. 41
Create Project Planp. 41
Measure Phasep. 55
Introductionp. 55
Define the Current Processp. 56
Process Mappingp. 64
Data Collection Plan, Metrics, and Operational Definitionsp. 84
Create a Baselinep. 97
Define the Detailed Voice of the Customer (VOC)p. 101
Interview Eventp. 101
Brainstorm Needsp. 104
Affinity Diagramsp. 105
Translate Needs to CTQp. 108
Survey Customers/Stakeholdersp. 115
Customer Needs Mapp. 116
Quality Function Deployment (QFD)p. 138
Define the Voice of the Process (VOP) and Current Performancep. 139
Benchmarkingp. 141
Check Sheetsp. 141
Plots, Capability and Statisticsp. 148
Pareto Charts, Time Series, Histogramsp. 149
Validate Measurement Systemp. 159
Define the Cost of Poor Quality (COPQ) and Cost/Benefitp. 164
Moving to the Analyze Phasep. 164
Analyze Phasep. 167
Introductionp. 167
Develop Cause-and-Effect Relationshipsp. 169
Test for Normality Exercisep. 172
Process Analysis and 8 Wastesp. 173
5Sp. 176
Failure Mode and Effects Analysisp. 177
Determine and Validate Root Causesp. 181
Regression Analysisp. 196
Hypothesis Testp. 196
Develop Process Capabilityp. 196
Process Capabilityp. 199
Improve Phasep. 207
Introductionp. 207
Identify Breakthrough and Select Practical Approachesp. 208
Action (Pilot) Planp. 210
Perform Cost/Benefit Analysisp. 211
Design Future Statep. 212
Establish Performance Targets and Project Scorecardp. 214
Gain Approval to Implement, Then Implementp. 222
Train and Executep. 222
Control Phasep. 231
Introductionp. 231
Measure Results and Manage Changep. 232
Report Scorecard Data and Create Process Control Planp. 235
FMEA and Control Planp. 235
Process Capability/DPMOp. 237
Apply P-D-C-A Processp. 240
Identify Replication Opportunitiesp. 242
Develop Future Plansp. 244
Conclusionsp. 247
Lean Six Sigma Glossaryp. 249
Indexp. 261
Table of Contents provided by Ingram. All Rights Reserved.

ISBN: 9781439828144
ISBN-10: 1439828148
Audience: Professional
Format: Paperback
Language: English
Number Of Pages: 280
Published: 14th October 2010
Publisher: Taylor & Francis Inc
Country of Publication: US
Dimensions (cm): 24.77 x 17.15  x 1.91
Weight (kg): 0.48
Edition Number: 1