Chapter 1 Introduction 1
PART I PROJECT ROADMAPS TO SOLVE BUSINESS PROBLEMS
Chapter 2 Define-Tools Roadmap Applied to the Beginning of All Projects 13
Chapter 3 Global Process Problems 23
A: On-Time Delivery Issues 23
B: Capacity of Process Is Too Low 27
C: RTY, Defects, Accuracy, Quality, Scrap, and Rework Issues 29
D: % Uptime Is Too Low 33
E: Pace of Process Too Slow 36
F: Process Has Enough Capacity, But Fails Intermittently 38
G: Process Has Enough Capacity, But Process Lead Time Is Too Long 41
H: Individual Steps Meet Takt, Global Process Does Not 44
I: Demand from the Customer Is Too Variable 47
J: Too Many Entity Types (Products) 51
K: High Schedule Variation 54
L: Measurement System Broken 60
M: Performance Characteristic Not Good Enough 63
N: Planned Maintenance Takes Too Long 64
O: Setup/Changeover Takes Too Long 65
P: Too Much Unplanned Maintenance 68
Q: Process Can't Make Product at All 72
R: Resource Usage Is Too High (Headcount Reduction) 75
S: Inventory Is Too High 78
T: Waste/Process Loss Too High 82
U: High Forecast Variation 85
V: Not Enough Sales 89
W: Backlog of Orders Is Too High 91
X: Payments Made to Suppliers Not Optimized 93
Y: Accounts Receivable Are Too High 95
Chapter 4 Individual Step Process Problems 99
Chapter 5 Control-Tools Used at the End of All Projects 107
PART II ROADMAPS TO FIND PROJECTS WHERE NO OBVIOUS CANDIDATES EXIST
Chapter 6 Discovery-Tools Applied to Identify Projects 115
PART III ROADMAPS TO GUIDE IN THE PRACTICAL APPLICATION OF EACH LEAN SIGMA TOOL
Chapter 7 Tools 119
01: 5 Whys 119
02: 5S 122
03: Affinity 130
04: ANOVA 133
05: Box Plot 141
06: Capability-Attribute 143
07: Capability-Continuous 146
08: Cause & Effect (C&E) Matrix 153
09: Chi-Square 157
10: Control Charts 163
11: Critical Path Analysis 171
12: Customer Interviewing 174
13: Customer Requirements Tree 183
14: Customer Surveys 186
15: Demand Profiling 193
16: Demand Segmentation 196
17: DOE-Introduction 202
18: DOE-Screening 213
19: DOE-Characterizing 222
20: DOE-Optimizing 237
21: Fishbone Diagram 249
22: Handoff Map 253
23: KPOVs and Data 257
24: Load Chart 268
25: MSA-Validity 272
26: MSA-Attribute 276
27: MSA-Continuous 284
28: Multi-Cycle Analysis 294
29: Multi-Vari Studies 300
30: Murphy's Analysis 306
31: Normality Test 308
32: Overall Equipment Effectiveness (OEE) 311
33: Pareto Chart 318
34: Poka Yoke (Mistake Proofing) 321
35: Process FMEA 325
36: Process Variables (Input/Output) Map 330
37: Project Charter 333
38: Pull Systems and Kanban 342
39: Rapid Changeover (SMED) 354
40: Regression 362
41: SIPOC 372
42: Spaghetti (Physical Process) Map 376
43: Statistical Process Control (SPC) 380
44: Swimlane Map 384
45: Test of Equal Variance 389
46: Time-Global Process Cycle Time 392
47: Time-Individual Step Cycle Time 395
48: Time-Process Lead Time 398
49: Time-Replenishment Time 401
50: Time-Takt Time 404
51: Total Productive Maintenance 408
52: t-Test-1-Sample 411
53: t-Test-2-Sample 416
54: t-Test-Paired 422
55: Value Stream Map 423
