World Class Applications of Six Sigma

Real World Examples of Success

Edited by

  • Jiju Antony, Professor of Quality Management and Deputy Director of the Institute of Operations management with the University of Strathclyde
  • Ashok Kumar, Seidman College of Business, Grand Valley State University, USA
  • Ricardo Banuelas, School of Engineering, University of Warwick, UK

World Class Applications shows what real organisations have done to implement Six Sigma, the methodology used, and the results delivered. The book provides details of how these organisations overcame issues with the statistical tools of Six Sigma and provides valuable lessons by explaining what went wrong when implementation failed. Cases cover topics including: Six Sigma in HR; Implementing Six Sigma in the Dow Chemical company; Six Sigma in IT; and Six Sigma to improve reporting quality.
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Quality management & improvement/engineering practitioners, Six Sigma practitioners & researchers; Six Sigma training courses; Advanced undergraduates in Business Admin, Business Studies, Quality Management & Technology & Mechanical, Chemical, Electronic & Manufacturing Engineering; Postgraduates taking MBAs, Quality Management, Manufacturing Systems Engineering, Engineering Business Management, Advanced Manufacturing Technology, Quality & Reliability; Post-experience students taking short courses in Quality Management, Manufacturing Management etc


Book information

  • Published: June 2006
  • ISBN: 978-0-7506-6459-2

Table of Contents

Six Sigma Implementation at Dow Chemical Company: A Comprehensive Review; Introduction;The Dow Chemical Company; The Six Sigma Program at Dow; Preamble and Preparation; The Six Sigma Journey; Dow’s Six Sigma Methodology at Variance; The Staircase of Change Leadership Model for Six Sigma Implementation; Six Sigma Project Organisational Structure; Six Sigma tools, Techniques, Software and Information technology; Tools and Techniques used by Dow for Six Sigma projects; Six Sigma Software; IT and Six Sigma at Dow; Where is Dow on its Six Sigma Journey?; Selected Case Studies; Energy Conservation Studies; Polycarbonate Unit Energy Reduction Project; System Unit Energy Envelopment Project; An Ergonomic Case Study (DMAIC Approach); Lessons and Insights from Dow’s Six Sigma program; Concluding Remarks; Manufacturing Waste Reduction Using Six Sigma Methodology; Introduction; Project Selection; Six Sigma Project: Re-winder Performance; Define Phase; Measure Phase; Analyse Phase; Improve Phase; Sub-system CTQ sigma level; Gap’s Transfer Function; Control Phase; Temporary Solution; Sustained solution; Process Capability; Control Plan; Conclusions; Process Improvement at TATA STEEL using the ASPIRE-DMAIC approach; Tata Steel Company; ASPIRE and Six Sigma at TATA STEEL; Project Selection; Introduction to the project; Purpose of Coke Quenching; Quenching process; ASPIRE DMAIC Approach; The Define Phase; The Measure Phase; The Analyse Phase; The Improve Phase; The Control Phase; Conclusion; Improving Product Reliability Using Six Sigma; Introduction; Six Sigma in the Collaborative Company; DMAIC Case Study; Define Phase; Define the Problem; Define the Advocacy team; Potential Financial Benefits; Project Charter; Measure Phase; Process Mapping; Identify potential causal factors; Identify stakeholders’ issues; Measurement System Analysis; Analysis Phase; Improve Phase; Control Phase; Financial confirmation of process capability; Stakeholder’s issues revisited; Agree line inspection frequency; Conclusion; Reducing the Engine Overheating problem in an Automotive Company using Six Sigma; Introduction; Case Study; Define Phase; Measure Phase; Analysis Phase; Improve Phase; Control Phase; Key results and financial savings generated from the project; Key ingredients of Six Sigma project implementation; Conclusion; An Application of Six Sigma Methodology to the manufacture of Coal Products; Introduction; Company background; Define Phase; Product, Customers and CTQs; Project Charter; Business Case; Statement of the Problem; Project Goal; Project Scope; Team formation; Milestones and Communications plan; Business process mapping; Measure Phase; Measurement System Analysis; Process Baseline; Process Description; Analyse Phase; Improve Phase; Control Phase; Economic Benefits obtained; Conclusions, comments and lessons learned; Six Sigma in Healthcare: A Case Study with CommonwealthHealth Corporation (CHC); Introduction to CHC; Why Six Sigma in CHC?; Six Sigma structure at CHC; Six Sigma Methodology; Benefits of Six Sigma; Critical Success Factors of Six Sigma in Healthcare; Clinical Project Example using DMAIC; Define; Measure; Analyse; Improve; Control; Conclusion; Six Sigma within Doosan Heavy Industries and Construction Company; Introduction; Background to Doosan Heavy Industry; Doosan’s Six Sigma Framework; Top level management commitment; Stakeholder involvement; Training scheme and project team activities; Measurement system; How to select project themes in Doosan?; Doosan’s Black Belt Course; Case Study; Define; Measure; Analyze; Improve; Control; Doosan’s Future Plans in Six Sigma; Lean Manufacturing and Six Sigma; Differences between Lean and Six Sigma; Synergy effect; Conclusion; Application of Six Sigma in Banking Industry; Introduction; Why Six Sigma in the Banking Industry?; Adoption of Six Sigma in the Banking Industry; Introduction to JP Morgan Chase and its use of Six Sigma; Introduction to JPMC Investors Services; Define; Measure; Analyze;Improve/Implement; Control and Project Results; Conclusion; Some Challenges of Six Sigma in the Banking Industry; Future Trends of Six Sigma in Banking; Six Sigma Approach to reducing fall hazards among cargo handlers working on top of cargo containers: a case study; Introduction and Background; Problem Statement; Details of cargo handling activities; Objectives and overview; Define; Past statistics on fall accidents in the cargo handling industry in Hong Kong; Interview surveys to establish the Working procedures; Measure; Preliminary interview; Measurement tree; Questionnaire development; Reliability of the questionnaire; Measurement I; Measurement II; Measurement III; Analyse; Critical factor I; Critical factor II; Critical factor III; Most critical procedure; Improve; Solution I; Solution II; Solution III;Solution IV;Control; Conclusion; Six Sigma for Government IT: Strategy & Tactics for Washington, DC; Introduction; Motivations; Six Sigma and Quality Concepts; Information Technology Infrastructure Library; Information Technology Infrastructure Library Maturity; Assessment and Improvement of Service Level Management; Assessment and Improvement of Capacity Management; Assessment and Improvement of Financial Management; Assessment and Improvement of Availability Management; Availability management - Define and Measure Phases; Availability Management – Analyse Phase and Benchmarking; Availability Management Conclusions; Assessment and Improvement of Service Continuity; Define, Measure and Analyse Phases for Service Continuity; Continuity Design Phase; Continuity Verify Phase; Conclusion; Increasing Newspaper Accuracy – A Case Study; Introduction; Define Phase; Measure Phase; Analyse Phase; Improve Phase; Control Phase; Results; Success Factors and lessons Learned; Deploying Six Sigma Company-wide; An Application of Six Sigma in Human Resources; Alan Harrison; Introduction; Before Improvements; Define Phase; People; Processes; Definition of customer needs and objectives; Measure; Key Performance Indicators; Cost of Poor Quality; Analyse; Improve; Control; Achieved Benefits; Conclusion