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Dedication
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Dedication
by V. Narayana, N. S. Sreenivasan
Continual Improvement Process
Cover
Title Page
Contents
Dedication
Preface
SECTION A AN OVERVIEW
CHAPTER 1 Total Quality Management with Six Sigma
Total quality management—meaning
TQM—eight fundamental principles
Variation
Six Sigma
TQM vs. Six Sigma
World trend in quality
Conclusion
CHAPTER 2 Continual Improvement and Competitive Edge
Context of quality
Expectations of the society
Competitive edge
Constituents of competitive edge
Competitive edge—differentiations and distinctiveness
Continual improvement—a larger perspective
Conclusion
CHAPTER 3 Basics of Continual Improvement Process
Continual improvement
Process and its potential
Zero defect level
Is zero defect level attainable?
Improvement as ‘restoration’ and ‘breakthrough’
Technology
Tools and techniques
Managerial practices
Model
Conclusion
Annexure 3A: Tools for quality and their brief description
CHAPTER 4 Process and Quality of Process
SIPOC—a process model
An overall understanding of continual improvement process
Defect
Sigma value of the process—a measure of quality
Conclusion
Annexure 4A: Guidelines on preparing defect checklist
SECTION B SCANNING METHODOLOGY TO CLEAN-UP AND SANITISE A PROCESS—FIRST STEP TO CONTINUAL IMPROVEMENT
CHAPTER 5 Process Analysis Against a Checklist of Process Requirements to be Met
Background
Checklist of requirements
Screening/review of process
Conclusion
Annexure 5A
CHAPTER 6 Process Analysis Through Flow Chart
Flow chart: technique
Flow chart: analysis
Process-centred approach
Conclusion
CHAPTER 7 Process Analysis: Interfering Factors and Action
Process interference
Checklist of interfering factors
Interferences: applicability and analysis
Relevance to continual improvement project/problem
Conclusion
CHAPTER 8 Process Analysis for Defect Prevention
Process review
Reference base—listing for review of process
Conclusion
Annexure 8A Self-control: an evaluation as applicable to manufacturing
CHAPTER 9 Process Analysis for Gaps in Specification
Specification
Gap analysis: listing of gaps in specification
Conclusion
Annexure 9A
Annexure 9B
Annexure 9C: Note on Juranian classification of quality needs
Annexure 9D: Analysis of customer requirements and their seriousness
CHAPTER 10 Process Analysis: Customer Interface
Customer link
Scrutiny of customer needs
Customer interface
Conclusion
CHAPTER 11 Failure Mode Effect Analysis
Background
Purpose
Meaning of FMEA
Analysis
Conclusion
Annexure 11A
Annexure 11B: Failure mode reference list
Typical key words and phrases
SECTION C MEASUREMENT OF PROCESS DEFECT LEVEL AND PROCESS CYCLE EFFICIENCY
CHAPTER 12 Basics of Six Sigma Technique
Background
Thought process of Six Sigma
Process, quality characteristic and specification
Specification, variation, process capability
Process capability and quality system
Statistical control
Normal law
Specification, process capability, defects and key thoughts of Six Sigma technique
Process capability and sigma value of the process
Obtaining the Sigma value of a process:
Obtaining the Sigma value of a process: z value from defect rate
Illustrative examples: Calculating
First time yield (FTY)
First time yield and
Rolled throughput of a process
A note on
Sustainability of improvement
Application of Six Sigma tool
Problem 1
Normalized yield
Process capability analysis (PCA)
Conclusion
Annexure 12A: Exercises on Six Sigma calculations
CHAPTER 13 Improving Process Flow and Speed to Achieve Lean Process
Background
Process flow and process speed
Checklist of factors having a bearing on process flow and speed
Lean Six Sigma
Addressing the factors of hold-up
Process set-up
Work in process, lead time and process cycle efficiency
Conclusion
SECTION D CONTINUAL IMPROVEMENT PROCESS FRAMEWORK
CHAPTER 14 Organising for Continual Improvement
Scope
The big picture of continual improvement
Strategy plan
Statistical techniques—understanding their importance
Micro-strategy
Guidelines to project selection
Authors’ observation on learning programmes
Conclusion
CHAPTER 15 Anchor Points of the Continual Improvement Thought Process
Background
Anchor points
Conclusion
Annexure 15A
Annexure 15B
Annexure 15C
CHAPTER 16 Involvement of People in Continual Improvement Process
Background
Productivity
Organising an enterprise
Continual improvement and productivity in an organization
Distinct features of a people-friendly environment
Reality check: Involvement
Impact of continual improvement
Conclusion
Annexure 16A
Annexure 16B
Annexure 16C
Annexure 16D
Annexure 16E
Annexure 16F Supplier base management
Annexure 16G
Annexure 16H
CHAPTER 17 Soft Skills for Effective Practice of Continual Improvement
Background
Communication
Communication gap
Violence in communication
Meeting
Impact on individuals
Conclusion
CHAPTER 18 Tools of Logical Thinking and Qualitative Analysis
Background
Quality thinking
Tools of qualitative analysis
Brain storming
Conclusion
CHAPTER 19 Tools and Techniques: Problem Solving Through Pattern Discovery and Probing
Background
Problem
Pattern discovery and investigation route
Data orientation
Tools and techniques
Frequency distribution/histogram
Break even point
Few approaches: critical incident analysis, engineering a failure and defect generation at levels that generate failures
Benchmarking
Conclusion
Annexure 19A
Annexure 19B
Annexure 19C
Annexure 19D
CHAPTER 20 Problem, Data and Interpretation of Data
Thought routine: problem and data
Reality check: problem formulation
A digression—reference to research in neurology on data
Investigation
Statistical linkage to investigation
Data on results and data on process
Statistical techniques
Data: a macro view
Conclusion
Annexure 20A
SECTION E STATISTICAL TECHNIQUES FOR INVESTIGATION AND IMPROVEMENT
CHAPTER 21 Measuring System
Importance of the measuring system
Measuring system: Illustration
Certain fundamental properties that define a ‘good’ measurement system
Traceability
Conclusion
Annexure 21A: Frame work of a system of control on measurements and measuring devices
CHAPTER 22 Measurement Process: Statistical Concepts
Measurement system ‘ideal’ but measurements are not identical
Pattern of variation: measurements
Statistical properties of measurement data
Measurement capability
Relationship: product specification and process capability and measurement system
Cause of bias/linearity, and inadequate repeatability and reproducibility
Conclusion
CHAPTER 23 Product/Process Comparison: Statistical Tests of Significance
Statistical significance
Conclusion
Illustrative example 1
Illustrative example 2
Illustrative example 3
Illustrative example 4
Illustrative example 5
Illustrative example 6
Illustrative example 7
Illustrative example 8
Illustrative example 9
Illustrative example 10
Annexure
Summary of statistical tests of significance
CHAPTER 24 Analysis of Frequencies, Analysis of Variance, Regression and Correlation Analysis
Analysis of frequency: illustration
Analysis of variance (ANOVA): Comparison of averages of more than two samples, one way classification
ANOVA: two-way classification
Regression analysis
Correlation analysis
Conclusion
CHAPTER 25 Technology Improvement: Application of Design of Experiments
Statistics, a key technology
Industrial experimentation
Taguchi’s methods
Principles of Taguchi’s methods
Design of experiments
An important observation
Understanding OA design
Standard OA designs and their linear graphs
Steps in designing, conducting and analysing an experiment
Analysis of experimental results: response by measurement (variable data)—Illustrative example 1
Analysis of experimental results: response by attribute data—illustrative example 2
Summary of results—average response of significant factors and interactions
Conclusion
Annexure 25A
SECTION F CONTINUAL IMPROVEMENT—MANAGERIAL ASPECTS
CHAPTER 26 Managing Continual Improvement Project
Background
Management commitment
Training programmes
Team building
Continual improvement projects—classification
Project team—route map for handling a project
Database
Overall assessments: continual improvement projects
Common reasons for setback in CIP
Key points to comply with for healthy environment
Synergistic impact
Conclusion
Annexure 26A
Annexure 26B
Annexure 26C
Annexure 26D
Annexure 26E
CHAPTER 27 Route Map for Handling a Project
Background
Discussion
Route map—DMAIC
Define stage
Measure stage
Analyse stage
Illustrative example 1: feedback from outpatients
Illustrative example 2: process speed investigation
Improve stage
Control stage
Illustrative example 3: analysis of difficulties in the purchase department
Assessment of each phase of DMAIC
Continual improvement Six Sigma, jargons
Conclusion
Annexure 27A
Annexure 27B
CHAPTER 28 Continual Improvement: Service Sector
Background
Peculiarities—non-profit institution
Peculiarities—service sector
Service industry: few new features of competitive edge
Training
Areas of concern
Conclusion
CHAPTER 29 Animal World and Self-improvement
Background
Role model
Conclusion
SECTION G CONTINUAL IMPROVEMENT—LARGER VITAL ISSUES
CHAPTER 30 Culture of Innovation and Improvement
Background
Vision—characteristic features
Vision—illustrative examples
Vision and institution
Clear vision
Entrepreneurship par excellence
Ventures of Prof. P. C. Mahalanobis
Recruitment—focus on the potential and not on track record
Unorthodoxy
Networking for brain irrigation
An observation
The
An urgent task
Conclusion
CHAPTER 31 Environment for Continual Improvement Process—Organisational Practices
Background
A long journey
Challenges ahead
People—the nucleus of an institution
Stephen Covey’s classification
Managerial practices
Institution and its individuals
Conclusion
SECTION H CONTINUAL IMPROVEMENT—STARTING OFF AND PRACTICAL HINTS
CHAPTER 32 From Where to Begin?
Background
Outlook on housekeeping
Benchmark
Cardinal principles
Issues covered
Conclusion
CHAPTER 33 Continual Improvement—Relevance to Individuals
Background
Individual and work
Work and Improvement
Conclusion
CHAPTER 34 Epilogue
Bibliography
Notes
Glossary
Acknowledgements
Copyright
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Preface
Dedicated to the sacred memory of
Sir M. Visvesvaraya, Bharat Ratna
and
J. R. D. Tata, Bharat Ratna
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