Preface .....................xi
Acknowledgments ............xiii
Chapter 1 Introduction ........1
1.1 History of Lean Six Sigma .........1
1.2 Optimal Quality Cost .................4
1.3 Benefits of Lean Six Sigma .......6
Chapter 2 Probability and Statistics .........11
2.1 Why is Statistics Relevant to Engineers? ................... 11
2.2 Probability, Sampling, and Random Variables .......... 13
2.3 Set Theory ..................15
2.4 Calculus of Probabilities ............ 17
2.5 System Probability as a Function of Subsystem Probabilities .......20
2.6 Law of Total Probability and Bayes' Theorem .......... 23
2.7 Probability Distributions and Cumulative
Distribution Functions ..............24
2.8 Expected Value and Variance .........27
2.9 Probability Distributions ..................28
2.10 The Central Limit Theorem ...........42
2.11 Statistical Data Analysis .......................................... 43
2.12 Graphical Methods ................................................. 44
Chapter 3 DMAIC: The Process of Lean Six Sigma .................. 51
3.1 Introduction ............................................................. 51
3.2 Six Sigma as a Statistical Measure ............................. 52
3.3 The DMAIC Process ................................................ 55
Chapter 4 Lean Six Sigma Tools .............................................. 69
4.1 SWOT, Affinity Diagram, SIPOC, VOC, CTQ ...... 69
4.2 Cp, Cpk, GR&R, Pareto Diagram, Prioritization Matrix, Normality Check, Monte Carlo Analysis .... 77
4.3 Confidence Intervals, Hypothesis Testing, Cause-and-Effect Analysis, FMEA, DOE, VSM ..... 85
4.4 RSM, Regression .................................................... 113
4.5 Statistical Process Control ...................................... 119
Chapter 5 Excel, MATLAB, Minitab, and other simulation tools .........129
5.1 Excel ..................................................................... 129
5.2 MATLAB .............................................................. 140
5.3 Minitab ................................................................. 145
5.4 R and Other Software Tools .................................. 154
Chapter 6 Lean Six Sigma Projects: Strategic Planning and Project Execution ..... 157
6.1 Strategic Planning and Deployment ...................... 157
6.2 Project Selection .................................................... 160
6.3 Lean Six Sigma Team ............................................ 162
6.4 Project Scope and Project Management ................. 164
6.5 Milestones, Deliverables, and Project Summary ..... 165
Chapter 7 Design for Six Sigma .........167
7.1 Overview: Quality at Low Costs ..........167
7.2 Process of DFSS ......... 178
7.3 Implementing DFSS ........ 204
7.4 Conclusions .............. 209
Chapter 8 Case Studies ............ 211
8.1 Lean Six Sigma Project-Pulse Width Modulation Control for Motor Speed ............211
8.2 DFSS Project-Vehicle-Occupant Safety Robust Design for Frontal Impact ........... 223
8.3 DFSS Project-Reliability Improvement of Car Window Regulator Operation ......... 230
Appendices ............ 239
Index ..................... 249
