Sigma Green Belt

8/12/2019 Sigma Green Belt

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The Six SigmaGreen Belt Handbook

H. James Harrington, Ph.D.Praveen GuptaFrank Voehl

R O F S S I O N LPaton ProfessionalChico, California


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CONTENTSAb out the Authors ixOther Books by H. James Ha rrington xiForeword xmChapter 1W ha t Is Six Sigma?You, as a Gr een Belt 1Definitions 1Histo ry of Six Sigma 2Using Sigma 4Th e Six Sigma Qu ality System 7Definin g th e Six Sigma Roles 9Training th e Six Sigma Team 15Imp leme nting Six Sigma in Large- and Medium-Sized Organizations 16Im ple m ent ing a Six Sigma System for a Small Org anization 17Six Sigma in Inform ation Tech nology (IT) 18Six Sigma Cha llenges 18Six Sigma Core Principles 20Six Sigma Key Co nce pts 20Yield 20Six Sigma No . 1 Principle 22Six Sigma System Results 24Successful Gre en Belt Projects 25Summary 29Chapter 2The Green Belt s RoleW ho Shou ld Be Selected to Become a Green Belt? 31How Do Green Belts an d Black Belts Work Together? 32W ha t is th e Six Sigma Body of Knowledge? 33Chapter 3Performing as a TeamTh e SST Leader 35Danc ing with a Bear 36Keys to Teamw ork 36Team Building 37


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Qua lities of Team Players 37Selecting SST Me mb ers 38SST Orie ntation 39Team Evolution and Relevant Relationships 39Team Developmen t 42Team Transitions 43Team Evolution 44Team Alignment 45DMAIC Tollgates 46Team Roles an d Responsibilities 46Team Gro und Rules 48Summary 50Chapter 4Basic Six Sigma Green Belt ToolsAffinity Diag ram 52Brainstorming 53Cause-and-Effect Analysis 56Checksheets 60Failure M ode an d Effect Analy sis (FMEA) 63Flowcharts * 64Force Field Analysis 74Graphs (Charts)Histograms 87Kano Model 91Nom inal Group Technique 96Chapter 5Six Sigma SoftwareQI Mac ros Power Tools for Lean Six Sigma 99Org anizin g Your Data in Excel 99QI Macros Introd uctio n 101Installing the QI Macros 101Samp le Test Data 102Creating a Chart Using a Macro from the Pull Down Men u 102Cre ating Run, Bar, or Pie Ch arts 103Blank Tem plates 103Creating a Con trol Chart with a Fill-in-the-Blanks Template 103Creating a Cha rt Using a Template 103Tem plates for Your Qu ality Im pro vem ent Efforts 106Streamlining the QI Story 106Co nvertin g Tables 106Data Sum marization with Pivot Tables 106Using ANOVA an d Oth er Analysis Tools 108Ana lyzing Cu stom er Service Data Hid den in Trouble-Rep orting Systems 108Im po rtin g Text w ith Microsoft Excel 109


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Analyzing Text wi th Excel 109Gra phing the Data 110Troublesho oting Problems 110QI Macro Learning Exercise I l l

Chapter 6Statistical Tools for Green BeltsProcess Elem ents, Variables, an d Ob servation s Co nce pts 114Data , Scale, an d Sources 114Data Accuracy 115Statistical Th ink ing 116Basic Statistical Co nce pts 117Mean 119Median 119Mode 120Range 120Variance 120Standard Deviation 120Corr elation Coefficient 121Histograms 121Basic Probab ility Co nce pts 122Probab ility The ory 122M utu ally Exclusive^Events 123Sampling < 124No rma l Distribution.- 125Binom ial Distribu tion 126Poisson Distrib ution 127Hyp othesis Testing 127Analysis of Varian ce (ANOVA) 128Ch i Square Test 128Six Sigma Measures 128Process Cap ability Study 130Cpk O perational (Long-Term) Process Cap ability 134CPU an d CPLUpper an d Lower Process Cap ability Indices 134CpkUsing the Factor M etho d 135Process Cap ability Analysis 136Statistical Process Co ntro l 138Variables Con trol Cha rts 143Attributes Con trol Cha rts 150Summary 154Chapter 7DMAIC OverviewDefinition of a Problem 158Different Levels of Cau ses 158Chara cteristics of Effective Problem Solving 158


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Ap plication of Scientific Th ink ing 159Root Cause Analysis 159Root Cause Analysis Tools 160Problem Solving Using th e DMAIC Process 160Th e Six Sigma Tollgates 161Phase Zero Problem /Opportunity Phase 162DMAIC Phase Objectives 165Summary 166Chapter 8The Six Sigma Define PhaseIntrodu ction to the Six Sigma Define Phase 170Tollgate No. Developth e SST Ch arter 172Selecting th e SST 174Building the Team Charter 175Project Scope 175Depe ndency and Relationship to Oth er Projects 176A Qualified Six Sigma Project 176Case Study 176Tollgate No . 1: Review Team Ch arter 177Tollgate No . 2: Define High-Level Process Maps an d Cu stom er Req uirem ents 179Tollgate No . 2 (Part 1): Define High-Level Process Map s 180Tollgate No. 2 (Part 2): Defining Custom er Requirem ents 183Voice of the Custo mer 185Voice of th e Cu stom er an d Voice of th e Business 185Co nduc t a SWOT Analysis 186Tollgate No . 3P reparing a Project Plan 190Summary 199Chapter 9The Six Sigma Measure PhaseIntrodu ction to the Six Sigma Measure Phase 204The Purpose of the Measure Phase 205Flowchart of Phase IIMeasure 206Tollgate No . 4: Create Data Co llection Plan 207Tollgate No. 5Implement Data Collection Plan 215Chapter 1The Six Sigma Analyze PhaseIntroduction to the Six Sigma Analyze Phase 219Tollgate No . 6Analyze the Data 222Six Basic Con cepts Involved in Six Sigma Analysis 224Better Use of Better Facts an d Data: From Events to Facts an d Data 228Uncovering Facts and Data Patterns 228Separating Signal from Noise 229Building Useful Data Mo dels 229


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Hy pothes is Testing an d Root Cause Analysis 231Tollgate N o. 7: Analyze th e Process 233Me asuring Process Performan ce 235Create Data Snapsh ots 236Envisioning the Process Intersections 237Perform a Poor-Q uality Cost Analysis 238Tollgate N o. 8: Analyze th e Root Cause(s) 241Root Cause Cod ing Worksheet 243Table of Typical Root Cause Codes 244Develop Opp ortunity /Proble m Statemen t and Project 245Chapter 11The Six Sigma Improve PhaseIntrod uction to the Six Sigma Improve Phase 250Tollgate No . 9: Gen erate Solutions 252Tollgate N o. 10: Select/Test Solutions 260Summary 268Chapter 12The Six Sigma C on trol PhaseIntrod uction to the Six Sigma Co ntrol Phase 272Tollgate No. 11 : Determine Methods of Control 274Tollgate No . 12: Imp leme nt the Imp rove me nt Plan 280Analyze an d Validate 282Summary 286Chapter 13Black Belt ToolsLean 287Design for Six Sigma 289Quality Function Dep loym ent: Defining Features and Function s 293DFMEA: An ticipatin g Problem s 293Project M anag em ent 294Design of Expe riments/Statistical Ap plications 295Does It End? 296Summary 297Acknowledgments 298Ap pe nd ix A: Glossary 299Ap pe nd ix B: The Six Sigma Body of Kn ow ledg e 317

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