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Tables of Contents for Six Sigma and Beyond
Chapter/Section Title
Page #
Page Count
Introduction Understanding the Six Sigma Philosophy
1
1
A Static versus a Dynamic Process
1
1
Products with Multiple Characteristics
2
2
Short- and Long-Term Six Sigma Capability
4
1
Design for Six Sigma and the Six Sigma Philosophy
5
2
Design Phase
5
1
Internal Manufacturing
5
1
External Manufacturing
6
1
References
7
2
Prerequisites to Design for Six Sigma (DFSS)
9
40
Partnering
9
16
The Principles of Partnering
11
1
View of Buyer/Supplier Relationship: A Paradigm Shift
11
1
Characteristics of Expanded Partnering
12
2
Evaluating Suppliers and Selecting Supplier Partners
14
1
Implementing Partnering
14
1
Establish Top Management Enrollment (Role of Top Management --- Leadership)
14
1
Establish Internal Organization
14
1
Option 1: Supplier Partnering Manager
14
1
Option 2: Supplier Council/Team
15
1
Option 3: Commodity Management Organization
15
1
Establish Supplier Involvement
15
1
Establish Responsibility for Implementation
15
2
Reevaluate the Partnering Process
17
1
Ratings
17
2
Terms Used in Specific Questions
19
1
Major Issues with Supplier Partnering Relationships
19
1
How Can We Improve?
20
1
Basic Partnering Checklist
21
1
Leadership
21
1
Information and Analysis
22
1
Strategic Quality Planning
22
1
Human Resource Development and Management
22
1
Management of Process Quality
23
1
Quality and Operational Results
23
1
Customer Focus and Satisfaction
23
1
Expanded Partnering Checklist
23
1
Leadership
23
1
Information and Analysis
24
1
Strategic Quality Planning
24
1
Human Resource Development and Management
24
1
Management of Process Quality
25
1
Quality and Operational Results
25
1
Customer Focus and Satisfaction
25
1
The Robust Team: A Quality Engineering Approach
25
9
Team Systems
26
1
Input
27
1
Signal
27
1
The System
27
1
Output/Response
28
1
The Environment
28
1
External Variation
28
1
Internal Variation
29
1
The Boundary
29
1
Controlling a Team Process: Conformance in Teams
29
1
Strategies for Dealing with Variation
30
1
Controlling or Eliminating Variation
30
1
Compensating for Variation
30
1
System Feedback
31
1
Minimizing the Effect of Variation
31
2
Monitoring Team Performance
33
1
System Interrelationships
33
1
Systems Engineering
34
6
``Systems'' Defined
34
1
Implications of the Systems Concept for the Manager
35
2
Defining Systems Engineering
37
1
Pre-Feasibility Analysis
38
1
Requirement Analysis
38
1
Design Synthesis
38
1
Verification
39
1
Advanced Quality Planning
40
7
When Do We Use AQP?
42
1
What Is the Difference between AQP and APQP?
43
1
How Do We Make AQP Work?
43
1
Are There Pitfalls in Planning?
43
1
Do We Really Need Another Qualitative Tool to Gauge Quality?
44
1
How Do We Use the Qualitative Methodology in an AQP Setting?
44
1
APQP Initiative and Relationship to DFSS
45
2
References
47
1
Selected Bibliography
47
2
Customer Understanding
49
48
The Concept of Function
52
16
Understanding Customer Wants and Needs
54
1
Creating a Function Diagram
55
1
The Product Flow Diagram and the Concept of Functives
56
5
The Process Flow Diagram
61
3
Using Function Concepts with Productivity and Quality Methodologies
64
4
Kano Model
68
3
Basic Quality
69
1
Performance Quality
69
1
Excitement Quality
69
2
Quality Function Deployment (QFD)
71
17
Terms Associated with QFD
73
1
Benefits of QFD
73
2
Issues with Traditional QFD
75
1
Process Overview
76
1
Developing a ``QFD'' Project Plan
76
1
The Customer Axis
77
2
Technical Axis
79
1
Internal Standards and Tests
79
1
The QFD Approach
79
1
QFD Methodology
80
4
QFD and Planning
84
2
Product Development Process
86
2
Conjoint Analysis
88
7
What Is Conjoint Analysis?
88
1
A Hypothetical Example of Conjoint Analysis
89
1
An Empirical Example
90
5
The Managerial Uses of Conjoint Analysis
95
1
References
95
1
Selected Bibliography
95
2
Benchmarking
97
72
General Introduction to Benchmarking
97
2
A Brief History of Benchmarking
97
1
Potential Areas of Application of Benchmarking
97
2
Benchmarking and Business Strategy Development
99
3
Least Cost and Differentiation
99
1
Characteristics of a Least Cost Strategy
100
1
Characteristics of a Differentiated Strategy
101
1
Benchmarking and Strategic Quality Management
102
17
Benchmarking and Six Sigma
105
2
National Quality Award Winners and Benchmarking
107
1
Example --- Cadillac
107
1
A Second Example --- Xerox
108
1
Third Example --- IBM Rochester
109
1
Fourth Example --- Motorola
110
1
Benchmarking and the Deming Management Method
110
1
Benchmarking and the Shewhart Cycle or Deming Wheel
111
1
Plan
111
1
Do
111
1
Study --- Observe the Effects
111
1
Act
111
1
Why Do People Buy?
111
1
Alternative Definitions of Quality
112
5
Determining the Customer's Perception of Quality
117
2
Quality, Pricing and Return on Investment (ROI) --- The PIMS Results
119
1
Benchmarking as a Management Tool
119
7
What Benchmarking Is and Is Not
120
1
The Benchmarking Process
121
1
Types of Benchmarking
122
1
Organization for Benchmarking
123
1
Requirements for Success
124
2
Benchmarking and Change Management
126
3
Structural Pressure
128
1
Aspiration for Excellence
128
1
Force Field Analysis
128
1
Identification of Benchmarking Alternatives
129
6
Externally Identified Benchmarking Candidates
129
1
Industry Analysis and Critical Success Factors
129
1
PIMS Par Report
130
1
Financial Comparison
130
1
Competitive Evaluations
131
1
Focus Groups
131
1
Importance/Performance Analysis
131
1
Internally Identified Benchmarking Candidates --- Internal Assessment Surveys
132
1
Nominal Group Process: General Areas in Greatest Need of Improvement
132
1
Pareto Analysis
132
1
Statistical Process Control
133
1
Trend Charting
133
1
Product and Company Life Cycle Position
133
1
Failure Mode and Effect Analysis
134
1
Cost/Time Analysis
134
1
Need to Identify Underlying Causes
134
1
Problem, Causes, Solutions
134
1
The Five Whys
134
1
Cause and Effect Diagram
134
1
Business Assessment --- Strengths and Weaknesses
135
4
Prioritization of Benchmarking Alternatives --- Prioritization Process
139
3
Prioritization Matrix
139
1
Quality Function Deployment (House of Quality)
140
1
Importance/Feasibility Matrix
141
1
Paired Comparisons
141
1
Improvement Potential
141
1
Prioritization Factors
141
1
Are There Any Other Problems? What Is the Relative Importance of Each of These?
142
1
Identification of Benchmarking Sources
142
7
Types of Benchmark Sources
142
1
Internal Best Performers
143
1
Competitive Best Performers
143
1
Best of Class
143
1
Selection Criteria
144
1
Sources of Competitive Information
144
4
Gaining the Cooperation of the Benchmark Partner
148
1
Making the Contact
149
1
Benchmarking --- Performance and Process Analysis
149
9
Preparation of the Benchmarking Proposal
149
1
Activity before the Visit
149
1
Understanding Your Own Operations
149
1
Activity Analysis
150
1
Define the Activity
150
1
Determine the Triggering Event
150
1
Define the Activity
150
1
Determine the Resource Requirements
151
1
Determine the Activity Drivers
151
1
Determine the Output of the Activity
151
1
Determine the Activity Performance Measure
151
1
Model the Activity
152
1
Examples of Modeling
152
1
Flow Chart the Process
153
2
Activities during the Visit
155
1
Understand the Benchmark Partner's Activities
155
1
Identification of All of the Factors Required for Success
155
1
Activities after the Visit
156
1
Functional Analysis
156
1
Cost Analysis
156
1
Technology Forecasting
156
1
Financial Benchmarking
157
1
Sales Promotion and Advertising
157
1
Warehouse Operations
157
1
PIMS Analysis
157
1
Purchasing Performance Benchmarks
157
1
Motorola Example
158
1
Gap Analysis
158
1
Definition of Gap Analysis
158
1
Current versus Future Gap
158
1
Goal Setting
159
2
Goal Definition
159
1
Goal Characteristics
159
1
Result versus Effort Goals
159
1
Goal Setting Philosophy
159
1
Best of the Best versus Optimization
159
1
Kaizen versus Breakthrough Strategies
160
1
Guiding Principle Implications
160
1
Goal Structure
160
1
Cascading Goal Structure
160
1
Interdepartmental Goals
161
1
Action Plan Identification and Implementation
161
2
A Creative Planning Process
162
1
Action Plan Prioritization
162
1
Action Plan Documentation
162
1
Monitoring and Control
162
1
Financial Analysis of Benchmarking Alternatives
163
1
Managing Benchmarking for Performance
164
2
References
166
1
Selected Bibliography
167
2
Simulation
169
18
What Is Simulation?
169
1
Simulated Sampling
170
5
Finite Element Analysis (FEA)
175
7
Types of Finite Elements
175
1
Types of Analyses
176
2
Procedures Involved in FEA
178
1
Steps in Analysis Procedure
178
1
Overview of Finite Element Analysis --- Solution Procedure
179
1
Input to the Finite Element Model
180
1
Outputs from the Finite Element Analysis
180
1
Analysis of Redesigns of Refined Model
181
1
Summary --- Finite Element Technique: A Design Tool
182
1
Excel's Solver
182
1
Design Optimization
182
3
How To Do Design Optimization
184
1
Understanding the Optimization Algorithm
184
1
Conversion to an Unconstrained Problem
185
1
Simulation and DFSS
185
1
References
186
1
Selected Bibliography
186
1
Design for Manufacturability/Assembly (DFM/DFA or DFMA)
187
36
Business Expectations and the Impact from a Successful DFM/DFA
189
3
The Essential Elements for Successful DFM/DFA
192
6
The Product Plan
194
1
Product Design
194
1
Criteria for Decision between Crash Program and Perfect Product
195
1
Case #1 --- Crash Program
195
1
Case #2 --- Perfect Product Design
196
1
The Product Plan --- Product Design Itself
196
2
Define Product Performance Requirement
198
1
Available Tools and Methods for DFMA
198
6
Cookbooks for DFM/DFA
199
1
Use of the Human Body
199
1
Arrangement of the Work Place
200
1
Design of Tools and Equipment
200
1
Mitsubishi Method
200
2
U-Mass Method
202
1
MIL-HDBK-727
203
1
Fundamental Design Guidance
204
2
The Manufacturing Process
206
2
Mistake Proofing
208
11
Definition
208
1
The Strategy
208
1
Defects
209
1
Mistake Proof System Is a Technique for Avoiding Errors in the Workplace
210
1
Types of Human Mistakes
210
1
Forgetfulness
210
1
Mistakes of Misunderstanding
210
1
Identification Mistakes
210
1
Amateur Errors
211
1
Willful Mistakes
211
1
Inadvertent Mistakes
211
1
Slowness Mistakes
211
1
Lack of Standards Mistakes
211
1
Surprise Mistakes
211
1
Intentional Mistakes
212
1
Defects and Errors
212
1
Mistake Types and Accompanying Causes
213
2
Signals that Alert
215
1
Approaches to Mistake Proofing
215
1
Major Inspection Techniques
216
1
Mistake Proof System Devices
216
1
Devices Used as ``Detectors of Mistakes''
217
1
Devices Used as ``Preventers of Mistakes''
217
1
Equation for Success
218
1
Typical Error Proofing Devices
219
1
References
219
1
Selected Bibliography
219
4
Failure Mode and Effect Analysis (FMEA)
223
64
Definition of FMEA
224
1
Types of FMEAs
224
1
Is FMEA Needed?
225
1
Benefits of FMEA
226
1
FMEA History
226
1
Initiation of the FMEA
227
1
Getting Started
228
7
Understand Your Customers and Their Needs
228
2
Know the Function
230
1
Understand the Concept of Priority
230
1
Develop and Evaluate Conceptual Designs/Processes Based on Customer Needs and Business Strategy
230
1
Be Committed to Continual Improvement
231
1
Create an Effective FMEA Team
231
3
Define the FMEA Project and Scope
234
1
The FMEA Form
235
18
Developing the Function
238
1
Organizing Product Functions
239
1
Failure Mode Analysis
240
1
Understanding Failure Mode
240
1
Failure Mode Questions
240
2
Determining Potential Failure Modes
242
1
Failure Mode Effects
243
1
Effects and Severity Rating
244
1
Severity Rating (Seriousness of the Effect)
245
1
Failure Cause and Occurrence
246
1
Popular Ways (Techniques) to Determine Causes
247
2
Occurrence Rating
249
1
Current Controls and Detection Ratings
249
1
Detection Rating
250
1
Understanding and Calculating Risk
251
2
Action Plans and Results
253
5
Classification and Characteristics
254
1
Product Characteristics/``Root Causes''
255
1
Process Parameters/``Root Causes''
255
1
Driving the Action Plan
255
3
Linkages among Design and Process FMEAs and Control Plan
258
2
Getting the Most from FMEA
260
2
System or Concept FMEA
262
1
Design Failure Mode and Effects Analysis (DFMEA)
262
6
Objective
263
1
Timing
263
1
Requirements
263
1
Discussion
263
1
Forming the Appropriate Team
263
1
Describing the Function of the Design/Product
264
1
Describing the Failure Mode Anticipated
264
1
Describing the Effect of the Failure
264
1
Describing the Cause of the Failure
264
1
Estimating the Frequency of Occurrence of Failure
265
1
Estimating the Severity of the Failure
265
1
Identifying System and Design Controls
265
1
Estimating the Detection of the Failure
266
1
Calculating the Risk Priority Number
267
1
Recommending Corrective Action
267
1
Strategies for Lowering Risk: (System/Design) --- High Severity or Occurrence
267
1
Strategies for Lowering Risk: (System/Design) --- High Detection Rating
267
1
Process Failure Mode and Effects Analysis (FMEA)
268
9
Objective
268
1
Timing
268
1
Requirements
268
1
Discussion
269
1
Forming the Team
269
1
Describing the Process Function
269
1
Manufacturing Process Functions
269
1
The PFMEA Function Questions
270
1
Describing the Failure Mode Anticipated
270
1
Describing the Effect(s) of the Failure
271
1
Describing the Cause(s) of the Failure
272
1
Estimating the Frequency of Occurrence of Failure
273
1
Estimating the Severity of the Failure
273
1
Identifying Manufacturing Process Controls
273
1
Estimating the Detection of the Failure
274
1
Calculating the Risk Priority Number
275
1
Recommending Corrective Action
275
1
Strategies for Lowering Risk: (Manufacturing) --- High Severity or Occurrence
275
1
Strategies for Lowering Risk: (Manufacturing) --- High Detection Rating
276
1
Machinery FMEA (MFMEA)
277
7
Identify the Scope of the MFMEA
277
1
Identify the Function
277
1
Failure Mode
277
1
Potential Effects
278
1
Severity Rating
279
1
Classification
279
1
Potential Causes
279
3
Occurrence Ratings
282
1
Surrogate MFMEAs
282
1
Current Controls
282
1
Detection Rating
282
1
Risk Priority Number (RPN)
282
1
Recommended Actions
283
1
Date, Responsible Party
283
1
Actions Taken/Revised RPN
283
1
Revised RPN
284
1
Summary
284
1
Selected Bibliography
284
3
Reliability
287
58
Probabilistic Nature of Reliability
287
1
Performing the Intended Function Satisfactorily
288
3
Specified Time Period
288
1
Specified Conditions
289
1
Environmental Conditions Profile
289
1
Reliability Numbers
290
1
Indicators Used to Quantify Product Reliability
290
1
Reliability and Quality
291
4
Product Defects
291
1
Customer Satisfaction
292
1
Product Life and Failure Rate
293
2
Product Design and Development Cycle
295
5
Reliability in Design
296
1
Cost of Engineering Changes and Product Life Cycle
297
1
Reliability in the Technology Deployment Process
298
1
Pre-Deployment Process
298
1
Core Engineering Process
299
1
Quality Support
300
1
Reliability Measures --- Testing
300
5
What Is a Reliability Test?
300
1
When Does Reliability Testing Occur?
301
1
Reliability Testing Objectives
301
1
Sudden-Death Testing
302
3
Accelerated Testing
305
1
Accelerated Test Methods
305
5
Constant-Stress Testing
305
1
Step-Stress Testing
306
1
Progressive-Stress Testing
306
1
Accelerated-Test Models
306
1
Inverse Power Law Model
307
1
Arrhenius Model
308
2
AST/PASS
310
2
Purpose of AST
310
1
AST Pre-Test Requirements
311
1
Objective and Benefits of AST
311
1
Purpose of PASS
311
1
Objective and Benefits of PASS
312
1
Characteristics of a Reliability Demonstration Test
312
2
The Operating Characteristic Curve
313
1
Attributes Tests
313
1
Variables Tests
314
1
Fixed-Sample Tests
314
1
Sequential Tests
314
1
Reliability Demonstration Test Methods
314
2
Small Populations --- Fixed-Sample Test Using the Hypergeometric Distribution
315
1
Large Population --- Fixed-Sample Test Using the Binomial Distribution
315
1
Large Population --- Fixed-Sample Test Using the Poisson Distribution
316
1
Success Testing
316
2
Sequential Test Plan for the Binomial Distribution
317
1
Graphical Solution
318
1
Variables Demonstration Tests
318
3
Failure-Truncated Test Plans --- Fixed-Sample Test Using the Exponential Distribution
318
1
Time-Truncated Test Plans --- Fixed-Sample Test Using the Exponential Distribution
319
1
Weibull and Normal Distributions
320
1
Sequential Test Plans
321
14
Exponential Distribution Sequential Test Plan
321
2
Weibull and Normal Distributions
323
1
Interference (Tail) Testing
323
1
Reliability Vision
323
1
Reliability Block Diagrams
323
2
Weibull Distribution --- Instructions for Plotting and Analyzing Failure Data on a Weibull Probability Chart
325
6
Instructions for Plotting Failure and Suspended Items Data on a Weibull Probability Chart
331
3
Additional Notes on the Use of the Weibull
334
1
Design of Experiments in Reliability Applications
335
1
Reliability Improvement through Parameter Design
336
1
Department of Defense Reliability and Maintainability --- Standards and Data Items
337
5
References
342
1
Selected Bibliography
343
2
Reliability and Maintainability
345
22
Why Do Reliability and Maintainability?
345
1
Objectives
346
1
Making Reliability and Maintainability Work
346
1
Who's Responsible?
347
1
Tools
347
1
Sequence and Timing
348
1
Concept
349
1
Bookshelf Data
349
1
Manufacturing Process Selection
350
1
R&M and Preventive Maintenance (PM) Needs Analysis
350
1
Development and Design
350
2
R&M Planning
350
1
Process Design for R&M
351
1
Machinery FMEA Development
351
1
Design Review
352
1
Build and Install
352
1
Equipment Run-Off
352
1
Operation of Machinery
352
1
Operations and Support
353
1
Conversion/Decommission
353
1
Typical R&M Measures
353
9
R&M Matrix
353
1
Reliability Point Measurement
354
1
MTBE
354
1
MTBF
355
1
Failure Rate
355
1
MTTR
355
1
Availability
356
1
Overall Equipment Effectiveness (OEE)
356
1
Life Cycle Costing (LCC)
356
1
Top 10 Problems and Resolutions
357
1
Thermal Analysis
357
2
Electrical Design Margins
359
1
Safety Margins (SM)
359
1
Interference
360
1
Conversion of MTBF to Failure Rate and Vice Versa
361
1
Reliability Growth Plots
361
1
Machinery FMEA
361
1
Key Definitions in R&M
362
2
DFSS and R&M
364
1
References
365
1
Selected Bibliography
365
2
Design of Experiments
367
90
Setting the Stage for DOE
367
5
Why DOE (Design of Experiments) Is a Valuable Tool
367
3
Taguchi's Approach
370
1
Miscellaneous Thoughts
371
1
Planning the Experiment
372
8
Brainstorming
372
1
Choice of Response
373
6
Miscellaneous Thoughts
379
1
Setting Up the Experiment
380
17
Choice of the Number of Factor Levels
380
2
Linear Graphs
382
1
Degrees of Freedom
383
1
Using Orthogonal Arrays and Linear Graphs
383
1
Column Interaction (Triangular) Table
384
1
Factors with Three Levels
385
1
Interactions and Hardware Test Setup
385
2
Choice of the Test Array
387
2
Factors with Four Levels
389
1
Factors with Eight Levels
389
1
Factors with Nine Levels
390
1
Using Factors with Two Levels in a Three-Level Array
390
1
Dummy Treatment
390
1
Combination Method
390
1
Using Factors with Three Levels in a Two-Level Array
391
1
Other Techniques
391
1
Nesting of Factors
392
1
Setting Up Experiments with Factors with Large Numbers of Levels
392
1
Inner Arrays and Outer Arrays
393
1
Randomization of the Experimental Tests
394
1
Miscellaneous Thoughts
394
3
Loss Function and Signal-to-Noise
397
8
Loss Function and the Traditional Approach
397
1
Calculation of the Loss Function
398
4
Comparison of the Loss Function and Cpk
402
1
Signal-to-Noise (S/N)
403
1
Miscellaneous Thoughts
404
1
Analysis
405
16
Graphical Analysis
405
2
Analysis of Variance (ANOVA)
407
1
Estimation at the Optimum Level
408
1
Confidence Interval around the Estimation
409
1
Interpretation and Use
410
1
ANOVA Decomposition of Multi-Level Factors
410
1
S/N Calculations and Interpretations
411
1
Smaller-the-Better (STB)
412
1
Larger-the-Better (LTB)
413
1
Nominal the Best (NTB)
413
2
Combination Design
415
3
Miscellaneous Thoughts
418
3
Analysis of Classified Data
421
9
Classified Responses
422
1
Classified Attribute Analysis
422
3
Class 1
425
1
Class 2
426
1
Classified Variable Analysis
426
2
Discussion of the Degrees of Freedom
428
1
Miscellaneous Thoughts
429
1
Dynamic Situations
430
11
Definition
430
1
Discussion
431
1
Conditions
431
1
Analysis
432
7
Miscellaneous Thoughts
439
1
For Example 1
440
1
For Example 2
440
1
Parameter Design
441
6
Discussion
441
1
Example
441
6
Tolerance Design
447
7
Discussion
447
1
Example
448
6
Humidity
454
1
Testing
454
1
DOE Checklist
454
1
Selected Bibliography
455
2
Miscellaneous Topics --- Methodologies
457
78
Theory of Constraints (TOC)
457
8
The Goal
457
1
Strategic Measures
458
1
Net Profit, Return on Investment, and Productivity
459
1
Measurement Focus
460
1
Throughput versus Cost World
461
1
Obstacles to Moving into the Throughput World
461
2
The Foundation Elements of TOC
463
1
The Theory of Non-Constraints
463
1
The Five-Step Framework of TOC
464
1
Selected Bibliography
465
1
Design Review
465
5
Failure Mode and Effect Analysis (FMEA)
467
3
References
470
1
Selected Bibliography
470
1
Trade-Off Studies
470
7
How to Conduct a Trade-Off Study: The Process
471
1
Construct the Preliminary Matrix
471
1
Select and Assemble the Cross-Functional Team
472
1
Assign Team Members' Roles and Responsibilities
472
1
Assign Ranking Teams To Evaluate the Alternatives
473
1
Identification of Ranking Methods
473
1
Development of Standardized Documentation
474
1
Timing for Report out of Selection Process
474
1
Weight the Various Categories
474
1
Compile the Evidence Book
475
1
Present the Results
475
1
Glossary of Terms
476
1
Selected Bibliography
477
1
Cost of Quality
477
34
Cost Monitoring System
478
1
Standard Cost
478
1
Actual Costs
478
2
Variance
480
1
Cost Reduction Efforts
480
1
Concepts of Quality Costs
480
1
J. Juran
480
1
W.E. Deming
480
1
P. Crosby
481
1
G. Taguchi
481
1
Definition of Quality Components
481
2
Methods of Measuring Quality
483
1
Complaint Indices
484
1
Processing and Resolution of Customer Complaints
484
1
Techniques for Analyzing Data
484
1
Format for Presentation of Costs
485
1
Laws of Cost of Quality
485
2
Data Sources
487
1
Inspection Decisions
487
1
Prevention Costs (See Table 10.5)
487
1
Appraisal Costs (See Table 10.6)
487
1
Internal Failure Costs (See Table 10.7)
487
1
External Failure Costs (See Table 10.8)
487
2
Diagnostic Guidelines to Identify Manufacturing Process Improvement Opportunities
489
1
Diagnostic Guidelines to Identify Administrative Process Improvement Opportunities
490
2
Steps for Quality Improvement --- Using Cost of Quality
492
1
Procedure
492
1
Examples
492
10
Guideline Cost of Quality Elements by Discipline
502
7
Cost of Quality and DFSS Relationship
509
2
References
511
1
Selected Bibliography
511
1
Reengineering
511
6
Process Redesign
511
1
The Restructuring Approach
512
1
The Conference Method
513
2
The OOAD Method
515
1
Reengineering and DFSS
516
1
References
517
1
Selected Bibliography
518
1
Geometric Dimensioning and Tolerancing (GD&T)
518
5
References
523
1
Selected Bibliography
523
1
Metrology
524
9
Understanding the Problem
524
1
Metrology's Role in Industry and Quality
525
2
Measurement Techniques and Equipment
527
1
Purpose of Inspection
528
1
How Do We Use Inspection and Why?
529
1
Methods of Testing
529
1
Interpreting Results of Inspection and Testing
530
1
Technique for Wringing Gage Blocks
531
1
Length Combinations
532
1
References
533
2
Innovation Techniques Used in Design for Six Sigma (DFSS)
535
18
Modeling Design Iteration Using Signal Flow Graphs as Introduced by Eppinger, Nukala and Whitney (1997)
535
4
Rules and Definitions of Signal Flow Graphs as Introduced by Howard (1971) and Truxal (1955)
538
1
Basic Operations on Signal Flow Graphs
538
1
The Effect of a Self Loop
538
1
Solution by Node Absorption
539
1
References
539
1
Selected Bibliography
540
1
Axiomatic Designs
541
6
So, What Is an Axiomatic Design?
542
1
Axiomatic and Other Design Methodologies
542
1
Applying Axiomatic Design to Cars
543
1
New Designs
544
1
Diagnosis of Existing Design
544
1
Extensions and Engineering Changes to Existing Designs
544
1
Efficient Project Work-Flow
545
1
Effective Change Management
545
1
Efficient Design Function
545
2
References
547
1
Selected Bibliography
547
1
TRIZ --- The Theory of Inventive Problem Solving
548
3
References
551
1
Selected Bibliography
551
2
Value Analysis/Engineering
553
46
Introduction to Value Control --- The Environment
553
2
History of Value Control
555
1
Value Concept
556
4
Definition
556
1
Planned Approach
556
1
Function
557
1
Value
557
1
Develop Alternatives
558
1
Evaluation, Planning, Reporting, and Implementation
559
1
The Job Plan
559
1
Application
560
1
Value Control --- The Job Plan
561
1
Value Control --- Techniques versus Job Plan
562
1
Techniques
562
1
Information Phase
563
19
Define the Problem
563
1
Information Development
564
1
Information Collection
564
1
Cost Visibility
564
1
Project Scope
565
2
Function Determination
567
1
Function Analysis and Evaluation
567
1
Cost Visibility
568
1
Definitions
568
2
Sources of Cost Information
570
1
Cost Visibility Techniques
570
1
Technique 1 --- Determine Manufacturing Cost
571
1
Technique 2 --- Determine Cost Element
571
1
Technique 3 --- Determine Component or Process Costs
571
1
Technique 4 --- Determine Quantitative Costs
572
1
Technique 5 --- Determine Functional Area Costs
573
1
Function Determination
573
1
What Is Function?
574
1
Basic and Secondary Functions
574
1
Basic Functions
574
1
Secondary Functions
575
1
Function Analysis and Evaluation
575
1
Technique 1 --- Identify and Evaluate Function
575
1
Technique 2 --- Evaluate Principle of Operation
576
1
Technique 3 --- Evaluate Basic Function
576
1
Technique 4 --- Theoretical Evaluation of Function
576
1
Technique 5 --- Input Output Method
577
1
Technique 6 --- Function Analysis System Technique
577
3
Cost Function Relationship
580
1
Evaluate the Function
580
2
Creative Phase
582
3
Phase 1. Blast
584
1
Phase 2. Create
584
1
Phase 3. Refine
584
1
Evaluation Phase
585
6
Selection and Screening Techniques
585
1
Pareto Voting
585
1
Paired Comparisons
586
1
Evaluation Summary
587
1
Matrix Analysis
587
2
Example
589
1
Rank and Weigh Criteria
589
1
Evaluate Each Alternative
590
1
Analyze Results
591
1
Implementation Phase
591
6
Goal for Achievement
592
1
Developing a Plan
592
1
Evaluation of the System
593
1
Understanding the Principles
593
1
Organization
594
2
Attitude
596
1
Value Council
596
1
Audit Results
597
1
Project Selection
597
1
Concluding Comments
598
1
References
598
1
Selected Bibliography
598
1
Project Management (PM)
599
18
What Is a Project?
599
2
The Process of Project Management
601
1
Key Integrative Processes
602
1
Project Management and Quality
603
1
A Generic Seven-Step Approach to Project Management
603
2
Phase 1. Define the Project
603
1
Step 1. Describe the Project
603
1
Step 2. Appoint the Planning Team
604
1
Step 3. Define the Work
604
1
Phase 2. Plan the Project
604
1
Step 4. Estimate Tasks
604
1
Step 5. Calculate the Schedule and Budgets
604
1
Phase 3. Implement the Plan
605
1
Step 6. Start the Project
605
1
Phase 4. Complete the Project
605
1
Step 7. Track Progress and Finish the Project
605
1
A Generic Application of Project Management in Implementing Six Sigma and DFSS
605
8
The Value of Project Management in the Implementation Process
607
1
Planning the Process
607
1
Goal Setting
608
1
PM and Six Sigma/DFSS
608
2
Project Justification and Prioritization Techniques
610
1
Benefit-Cost Analysis
610
1
Return on Assets (ROA)
610
1
Return on Investment (ROI)
610
1
Net Present Value (NPV) Method
611
1
Internal Rate of Return (IRR) Method
611
1
Payback Period Method
612
1
Project Decision Analysis
612
1
Why Project Management Succeeds
613
2
References
615
1
Selected Bibliography
615
2
Limited Mathematical Background for Design for Six Sigma (DFSS)
617
44
Exponential Distribution and Reliability
617
8
Exponential Distribution
617
1
Probability Density Function and Cumulative Distribution Function
618
1
Probability Density Function (Decay Time)
618
1
Cumulative Distribution Function (Rise Time)
618
1
Reliability Problems
618
1
Constant Rate Failure
619
1
Example
619
2
Probability of Reliability
621
1
Control Charts
621
1
Continuous Time Waveform
621
1
Discrete Time Samples
621
1
Digital Signal Processing
622
1
Sample Space
622
2
Assigning Probability to Sets
624
1
Gamma Distribution
625
15
Gamma Distribution (pdf)
625
1
Gamma Function
626
1
Properties of Gamma Functions
626
1
Gamma Distribution and Reliability
627
1
Example 1: Time to Total System Failure
627
1
Gamma Distribution and Reliability
628
4
Reliability Relationships
632
1
Reliability Function
632
1
Data Failure Distribution
633
1
Failure Rate or Density Function
633
1
Hazard Rate Function
634
1
Relations between Reliability and Hazard Functions
634
1
Poisson Process
635
1
Characteristics of Poisson Process
636
1
Poisson Distribution
636
3
Example
639
1
Weibull Distribution
640
4
Three-Parameter Weibull Distribution
643
1
Taylor Series Expansion
644
12
Taylor Series Expansion
645
4
Partial Derivatives
649
1
Taylor Series in Two-Dimensions
649
1
Taylor Series of Random Variable (RV) Functions
650
1
Variance and Covariance
650
1
Functions of Random Variables
651
1
Division of Random Variables
651
1
Powers of a Random Variable
652
1
Exponential of a Random Variable
652
1
Constant Raised to RV Power
653
1
Logarithm of Random Variable
653
1
Example: Horizontal Beam Deflection
654
1
Example: Difference between Two Means
655
1
Miscellaneous
656
2
Closing Remarks
658
1
Selected Bibliography
658
3
Fundamentals of Finance and Accounting for Champions, Master Blacks, and Black Belts
661
54
The Theory of the Firm
661
1
Budgets
662
1
Our Romance with Growth
663
1
The New Industrial State
663
1
Behavioral Theory
663
1
Accounting Fundamentals
664
15
Accounting's Role in Business
664
1
Financial Reports
664
1
The Balance Sheet
664
1
Current Assets and Liabilities
665
1
Fixed Assets
665
1
Other Slow Assets
666
1
Current Liabilities
666
1
Working Capital Format
666
1
Noncurrent Assets
667
1
Noncurrent Liabilities
667
1
Shareholders' Equity
667
1
The Income Statement
667
1
Gross Profit
668
1
A Gaggle of Profits
668
1
Earnings per Share
669
1
The Statement of Changes
669
1
Sources of Funds or Cash
669
1
Use of Funds
670
1
Changes in Working Capital Items
670
1
The Footnotes
670
1
Accountants' Report
671
1
How to Look at an Annual Report
671
1
Recording Business Transactions
672
1
Debits and Credits
673
1
Sources and Uses of Cash
673
1
How Debits and Credits Are Used
673
1
The Balance Sheet Equations
673
1
Classification of Accounts
674
1
Recording Transactions
675
1
The Two Books of Account
675
1
The Trial Balance
676
1
The Mirror Image
676
1
Accrual Basis of Accounting
676
1
Accrual Basis versus Cash Basis
677
1
Details, Details
677
1
Birth of the Balance Sheet
678
1
Profits versus Cash
678
1
Things Are Measured in Money
678
1
Values Are Based on Historical Costs
678
1
Understanding Financial Statements
679
9
Assets
679
1
The Inflation Effect
679
1
Summary of Valuation Methods
679
1
Historical Cost
679
1
Liquidation Value
679
1
Investment or Intrinsic Value
680
1
Psychic Value
680
1
Current Value or Replacement Cost
680
1
Assets versus Expenses
680
1
Types of Assets
681
1
Financial Assets
681
1
Physical Assets
681
1
Operating Leverage
682
1
Determining the Value of Inventory
682
1
FIFO
682
1
LIFO
682
1
Weighted Average
683
1
Depreciation
683
1
Useful Life Concept
683
1
Depreciation as an Expense
684
1
Depreciation as a Valuation Reserve
684
1
Depreciation as a Tax Strategy
684
1
Depreciation as Part of Cash Flow
685
1
Straight Line
685
1
Sum-of-the-Years' Digits (SYD)
686
1
Double Declining Balance (DDB)
686
1
Unit of Production
687
1
Replacement Cost
687
1
Advantages of Accelerated Depreciation
687
1
Financial Statement Analysis
688
7
Ratio Analysis
688
3
Liquidity Ratios
691
1
Financial Leverage
692
1
Coverage Ratios
692
1
Earnings
692
1
Earnings Ratios
693
1
Le ROI
693
1
ROE: Return on Equity
694
1
ROA: Return on Assets
694
1
ROS: Return on Sales
694
1
Other Return Ratios
694
1
Financial Rating Systems
695
4
Bond Rating Companies
695
1
Moody's et al.
695
1
Moody's
696
1
Standard and Poor's
696
1
Ratings on Common Stocks
696
1
The S&P Rating Method
697
1
The Value Line Method
697
1
Good Ole Ben Graham
697
1
Commercial Credit Ratings
698
1
Dun & Bradstreet
698
1
Other Systems
699
1
Company and Product Life Cycle
699
5
Cash Flow
700
1
A Final Thought about Cash Flow
701
2
A Handy Guide to Cost Terms
703
1
Useful Concepts for Financial Decisions
704
6
The Modified duPont Formula
704
1
Breakeven Analysis
705
1
Contribution Margin Analysis
706
1
Price-Volume Variance Analysis
707
1
Inventory's EOQ Model
707
1
Return on Investment Analysis
708
1
Net Present Value (NPV)
709
1
Internal Rate of Return (IRR)
709
1
Profit Planning
710
2
The Nature of Sales Forecasting
710
1
The Plans Up Form
710
1
Statistical Analysis
711
1
Compound Growth Rates
711
1
Regression Analysis
711
1
Revenues and Costs
711
1
Departmental Budgets
711
1
How to Budget
712
1
Zero-Growth Budgeting
712
1
Selected Bibliography
712
3
Closing Thoughts about Design for Six Sigma (DFSS)
715
10
Appendix The Four Stages of Quality Function Deployment
725
6
Stage 1: Establish Targets
725
1
Stage 2: Finalize Design Timetables and Prototype Plans
725
1
Stage 3: Establish Conditions of Production
725
1
Stage 4: Begin Mass Production Startup
726
1
Tangible Benefits
726
1
Intangible Benefits
727
1
Summary Value
727
1
The QFD Process
727
1
Managing the Process
728
3
Selected Bibliography
731
6
Index
737