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by Roger Hoerl, Ron D. Snee
Leading Holistic Improvement with Lean Six Sigma 2.0, Second edition
Cover Page
Title Page
Copyright Page
Dedication
Contents at a Glance
Contents
About This E-Book
Acknowledgments
About the Authors
Preface
Chapter 1 A New Paradigm Is Needed
The Expansion to Lean Six Sigma
Macro Societal Shifts Since 1987
Accelerated Globalization
Massive Immigration into North America and Europe
Growth of IT and Big Data Analytics
Recognition of Uniqueness of Large, Complex, Unstructured Problems
Modern Security Concerns
Current State of the Art
Versions 1.0 and 1.1
Version 1.2: Lean Six Sigma
Version 1.3: Lean Six Sigma and Innovation
The Limitations of Lean Six Sigma 1.3
Still Not Appropriate for All Problems
Does Not Incorporate Routine Problem Solving
Not a Complete Quality Management System
Inefficient at Handling Large, Complex, and Unstructured Problems
Does Not Take Advantage of Big Data Analytics
Does Not Address Modern Risk Management Issues
A New Paradigm Is Needed
References
Chapter 2 What Is Holistic Improvement?
The Ultimate Objective: Comprehensive Improvement
A Holistic View of Improving the Business
An Example of Holistic Improvement
A Strategic Structure for the Holistic Improvement System
Creating a Common Improvement System: The Case of Lean Six Sigma
An Integrated Project Management System
Summary and Looking Forward
References
Chapter 3 Key Methodologies in a Holistic Improvement System
Six Sigma: An Overall Framework and One Option for Improvement Projects
Quality by Design Approaches
Innovation and Creativity
Design for Six Sigma (DFSS)
Quality Function Deployment (QFD)
Theory of Inventive Problem Solving (TRIZ)
Additional Breakthrough Improvement Methods
Lean Enterprise
Statistical Engineering
Big Data Analytics
Work-Out Approach
Quality and Process Management Systems
ISO 9000
Malcolm Baldrige National Quality Award
Kepner—Tregoe Approach
Total Productive Maintenance (TPM)
The Internet of Things
Summary and Looking Forward
References
Chapter 4 Case Studies in Holistic Improvement
Case Study: Inside the GE Deployment
The Beginnings: Jack Never Bluffs!
No Second Guessing
The First Year: 1996
The Push for Tangible Benefits
DFSS and a Critical Mass of Green Belts
A Refocus on Customers
Application to Finance
Digitization and Six Sigma
At the Customer, for the Customer (ACFC)
An Expansion and Reinvigoration
Connection to Innovation and New Product Development
Lessons Learned
Case Study: The DuPont Story
Improvement at DuPont: 1950–1990s
Strategy of Experimentation
Product Quality Management
Other Approaches
Six Sigma Begins in 1998
Creating a Holistic System
DuPont Production System
DuPont Integrated Business Management
Product Commercialization Framework
Lessons Learned
Case Study: The Scott Paper Experience with Holistic Improvement
Process Control Initiative
Parallel Efforts
Early Efforts Toward Lean Design
Reorganization of the Quality Organization
Quality by Design
Early Attempts at Integration
Lessons Learned
Summary and Looking Forward
References
Chapter 5 How to Successfully Implement Lean Six Sigma 2.0
Why Are Organizations Successful in Implementing Lean Six Sigma?
Some Common Misconceptions
Success Starts at the Top
Lean Six Sigma Requires Top Talent
An Infrastructure to Support the Effort
Why Were Others Less Successful?
How Committed Was Senior Leadership?
Who Was Selected for Key Lean Six Sigma Roles?
A Lack of Supporting Infrastructure
The Keys to Successful Lean Six Sigma Deployment
Committed Leadership
Top Talent
Supporting Infrastructure
Improvement Methodology Portfolio
High-Level Roadmap for Lean Six Sigma 2.0 Deployment
Launching the Initiative
Managing the Effort
Sustaining Momentum and Growing
The Way We Work
Summary and Looking Forward
References
Chapter 6 Launching the Initiative
Full or Partial Deployment?
Developing the Deployment Plan
Deployment Plan Elements
Strategy and Goals
Process Performance Measures
Project Selection Criteria
Project Identification and Prioritization System
Deployment Processes for Leaders
Roles of Management and Others
Curricula and Training System
Project and Initiative Review Schedule
Project Reporting and Tracking System
Audit System for Previously Closed Projects
Reward and Recognition Plan
Communications Plan
Selecting the Right Projects
Six Sigma and Lean Projects
Selecting Good Lean Six Sigma Projects
The Concept of Process Entitlement
Developing the Project Charter
Selecting the Right People
The Leadership Team
Champion
Black Belt
Green Belt
Master Black Belt
Functional Support Groups
Forming Teams
Where Do I Find the Resources?
What Training Do I Need?
Sample Black Belt Course for Finance
Sample Black Belt Course for Manufacturing
Sample Green Belt Course for Manufacturing
Selecting a Lean Six Sigma Provider
Summary and Looking Forward
References
Chapter 7 Managing the Effort
Managerial Systems and Processes
Management Project Reviews
Project Reporting and Tracking
Communications Plan
Reward and Recognition Plan
Project Identification and Prioritization
Project Closure: Moving On to the Next Project
Lean Six Sigma Budgeting
Deployment Processes for Leaders
Integrating Lean Six Sigma with Current Management Systems
Summary and Looking Forward
References
Chapter 8 Sustaining Momentum and Growing
Playing Defense: Sustaining Momentum
Holding Project Gains
Quarterly and Annual Reviews
The Training System
Leadership Green Belt Training
Lean Six Sigma Organizational Structure
Six Sigma Leaders Must Work Together As a Team
The “Lean Six Sigma Sweep”
Playing Offense: Growing the Effort
Expanding Lean Six Sigma Throughout the Organization
Using Six Sigma to Improve Supplier Performance
Expanding the Improvement Portfolio
Which Methodologies to Add?
Implications for Infrastructure
Selecting the Most Appropriate Methodology
Growing the Top Line
Summary and Looking Forward
References
Chapter 9 The Way We Work
Creating a Holistic Improvement System
The Improvement Project Portfolio
The Improvement Organization
Integration of Quality and Process Management Systems
Synergies with ISO 9000
Synergies with the Malcolm Baldrige National Quality Award
Synergies with Risk Management
Don’t Forget About Process Control
Don’t Forget About Managerial Processes
Motorola Financial Audit Case
The Long-Term Impact of Holistic Improvement
Holistic Improvement Drives Culture Change
Improvement As a Leadership Development Tool
Summary and Looking Forward
References
Chapter 10 Final Thoughts for Leaders
Understanding the Role of the Methods and Tools: A Case Study
Define Phase
Measure Phase
Analyze Phase
Improve Phase
Control Phase
Results
How to Think About the Methods and Tools
Tools Themselves Don’t Make Improvements
Tools Must Be Properly Sequenced
Leadership Is Still Required
Incorporate Subject Matter Knowledge
Summary and Looking Forward
References
Appendix A Ensuring Project and Initiative Success
Appendix B Glossary
Appendix C Acronyms
Index
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Copyright Page
L
EADING
H
OLISTIC
I
MPROVEMENT WITH
L
EAN
S
IX
S
IGMA
2.0
Second Edition
Ronald D. Snee
Roger W. Hoerl
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