5793Index.qxd_rf 6/11/04 3:00 PM Page 699

I NDEX

A Barriers against transformation, 684 α risk, 339, 683 Bias over domain, 109, 684 Activating a Six Sigma project team, 62 Bias over time, 109 Additive flag system, 683 Bimodal, 254 Affinity diagram, 81, 468–472, 683 Binary key indicators, 684 Aids for transformation, 683 Binomial distribution, 292, 684 Algebra, 652–655 characteristics of, 295–296 Alias, 399 equation for, 294 Alternative hypothesis, 335, 683 properties, 292 Among group variation, 355 Black belt, 28, 684 Analysis of Variance (ANOVA), 683 Blocking, 173, 684 one-way, 353–359 Bottleneck, 148, 684 summary table, 356 Box-and-whisker plot, 256–259, 349, 361, 684 Analytical studies, 231, 683 Brainstorming, 464–468, 684 Analyze phase, 36–38, 145–191, 514–527, Brown belt, 684 560–565, 683 Business case, 66, 684 Application window, 260 Business objectives, 684 Area of opportunity, 433–434 Arithmetic, 650–652 C Arithmetic mean, 243–244, 683 c chart, 137, 433–436, 512–513, 615 Assumptions, Calibration, 109, 684 of ANOVA, 360–361 Cancel command button, 263 of the confidence interval for the mean, 323 Cause-and-effect diagram, 149, 151, 214, 472–473, of the confidence interval for the proportion, 684 328 Cause-and-effect matrix, 151, 685 of the F test for the difference between two Central limit theorem, 317 variances, 353 Champion, 27, 685 of the pooled variance t test, 349 Change-many-factors-at-once design, 195, 684 Attractive Kano category, 683 Check box, 263 Attribute check sheet, 162, 473–475, 683 Check sheets, 685 Attribute control charts, 418 Circumstantial data, 79, 685 Attribute data, 235, 683 Classical approach to probability, 280, 685 Attributer key indicators, 683 Click, 260 Attribute process capability, 684 Cluster sample, 234, 685 Cognitive images, 82, 685 B Collectively exhaustive, 282, 685 β risk, 339, 684 Common causes of variation, 419 Background variable, 371 Common variation, 8, 685 Bar chart, 236, 684 Completely randomized design, 355, 685

699 5793Index.qxd_rf 6/11/04 3:00 PM Page 700

700 Index

Confidence coefficient, 338 Defect location check sheet, 163–165, 476, 686 Confidence interval estimate, 321, 685 Defect opportunity, 32, 686 of the mean, 322–325 Defects per million opportunities (DPMO), 32, 686 of the proportion, 326–328 Defects per opportunity (DPO), 32, 686 Confounded, 398, 685 Defects per unit (DPU), 32, 686 Continuous improvement view of quality, 12–14 Define phase, 35, 61–101, 491–506, 543–552, 687 Contingency plans, 156, 685 Defining contrast, 398 Continuous improvement view of quality, 685 Degrees of freedom, 356, 687 Control charts, 685 Dependent variable, 194, 371, 687 attribute charts, 418 Descriptive statistics, 127, 135, 137, 230, 687 c chart, 137, 433–436, 512–513, 615 Design of experiments, 687 flow diagram for selecting, 454 Detection scale, 156, 687 individual value and moving range chart, 64, Diffusion, 224, 687 112, 135, 213, 224, 449–453, 492, 511, Discrete variable, 287 534–535, 537, 543, 576, 616 Dispersion, 249 p-chart, 429–433, 582, 614 DMAIC model, 35–38, 687 rules for determining out-of-control points, analyze phase, 36–38, 145–191, 514–527, 427–429 560–565, 683 table of factors, 678–679 control phase, 38, 217–226, 535–536, 578–585, X and R charts, 127, 168, 169–172, 212, 685 440–444, 611 define phase, 35, 61–101, 491–506, 543–552, X and S charts, 444–448 687 u-chart, 436–439 improve phase, 38, 193–216, 528–535, variable charts, 418 565–578, 689 Controllable nuisance variable, 172, 686 measure phase, 36, 103–143, 507–514, Control limits, 426 552–560, 691 Control phase, 38, 217–226, 535–536, 578–585, Dot plot, 136, 138, 168–171, 179–184, 241, 685 512–513, 520–524, 576, 623–624, 687 Control plan, 686 Double-click, 260 Convenience sample, 232 Drag, 260 Cost avoidance, 686 Drop-down list box, 263 Cost reduction, 686 Crisis, 686 E Critical value of the test statistic, 336, 337, 686 Early adopters, 225, 687 CTQ, 31, 686 Early majority, 225, 687 Customer satisfaction key objectives, 686 Edit box, 263 Elementary event, 280 D Empirical approach to probability, 281 Dashboard, 45, 686 Employee growth and development key objectives, components, 47–52 687 strategic benefits, 46 Enumerative studies, 230, 687 structure, 46 Estimated effects, tactical benefits, 46 computing, 382–383, 388–390 Data, 235, 686 Event, 280, 687 Data file documentation, 681–682 Executive committee, 26, 687 Decrease project or task, 686 Expected value, 288, 687 Defect, 32, 686 Experimental error, 355 Defective, 32, 686 Experimental run, 687 5793Index.qxd_rf 6/11/04 3:00 PM Page 701

Index 701

F Indifferent Kano category, 689 F distribution, 687 Individual value and moving range chart, 64, 112, tables of, 670–677 135, 213, 224, 449–453, 492, 511, 534–535, Factorial designs, 372, 383–397, 687 537, 543, 576, 616 Failure modes and effects analysis (FMEA), Inferential statistics, 230, 689 154–156, 688 Innovators, 689 Feedback loop, 10, 688 Intangible costs, 689 Financial key objectives, 688 Interaction effects, 178, 377, 625, 689 Five-number summary, 255–256, 688 Interaction plots, 178, 186–187, 202, 378, 380, Flag diagrams, 50–51, 688 386, 396, 403, 408, 525, 527, 530, 571, 630, Flowchart, 75, 688 689 Focus points, 688 International Standards Organization (ISO), Fractional factorial design, 194, 397, 688 218–220, 689, 690 Frame, 231, 688 Funnel experiment, 420–426 J Full factorial design, 194, 688 J-shaped cost distribution, 89, 690 Judgment sample, 232 G Gage R & R run chart, 116, 121, 510, 556 K Gage R & R study, 113, 116, 118, 119, 123, 688 Kano quality category, 83, 86 Gantt chart, 71, 480–483, 497, 545, 688 Kano questionnaire, 83, 86, 87, 504, 690 Gantt chart key indicators, 688 Key indicators, 49–50, 690 Gap, 231 Key objectives, 47–49, 690 Goalpost view of quality, 11, 688 Goal statement, 68, 688 L Graphic, 688 Laggards, 225, 690 Green belt, 29, 598, 689 Late majority, 225, 690 Green belt certification, 598, 689 Lead user, 78, 690 Lean management, 146 H Left-skewed, 253 Half-normal plot, 387, 689 Level of significance, 338, 690 Hard benefits, 70, 689 Levene test, 354–355, 362–363, 690 Heavy user, 78, 689 Likelihood of occurrence scale, 156, 690 Help command button, 263 Linearity, 109, 690 Histogram, 65, 128, 240, 492, 559, 610, 689 Line chart, 238, 690 Homogeneity of variance assumption, 361 List box, 263 Hypothesis, 177, 689 List key indicators, 690 Hypothesis testing, 334, 689 Local steering team, 690 p-value approach, 341–342 Lower specification limit, 691 seven-step method, 340–341 Lurking variable, 173, 242, 371, 691

I M Improve phase, 38, 193–216, 528–535, 565–578, Main effects plot, 185, 186, 202, 377, 380, 386, 689 395, 402, 407, 525–526, 531, 571, 625, Increase project or task, 689 630 Independence, 285, 689 Marketing mix, 691 Independence assumption, 361 Market segmentation, 77, 691 Independent variables, 194, 371, 689 Master black belt, 27–28, 691 701 5793Index.qxd_rf 6/11/04 3:00 PM Page 702

702 Index

Mean squares, 198, 356, 373, 691 pareto chart, 269–271 MSA, 374 poisson distribution, 312 MSAB, 374 project manager, 265 MSB, 374 projects, 264 MSE, 374 random sampling, 277 Measurement data, 235, 691 run chart, 271 Measurement key indicators, 691 session, 264 Measurement system analysis checklist, 110–111, testing for the difference between two means, 691 365–366 Measurement check sheet, 475, 691 testing for the difference between two Measure phase, 36, 103–143, 507–514, 552–560, proportions, 364–365 691 testing for the difference between two Measures of central tendency, variances, 366 arithmetic mean, 243–244 two-way ANOVA, 409 median, 243, 246–247 u-chart, 457–458 mode, 243, 247 worksheets, 265 Measures of variation, X and R charts, 458–460 range, 250 X and S charts, 460–461 standard deviation, 250–253 Zone limits for control charts, 455 variance, 250–253 Minitab dialog boxes, Median, 243, 246–247, 691 Analyze Factorial Design, 413 Minitab, Analyze Factorial Design—Graphs, 414 application window, 261 Analyze Factorial Design—Terms, 413, 415 bar chart, 268–269 bar charts, 269 binomial distribution, 311 bar charts—values from a table, 269 box-and-whisker plot, 276 binomial distribution, 311 c-chart, 456–457 Boxplots, 276 cause-and-effect diagram, 485 Boxplots—One Y, Simple, 276 confidence interval estimate for the mean, c-chart, 457 329–330 calculator, 271 confidence interval estimate for the proportion, cause-and-effect diagram, 486 330–331 cause-and-effect diagram—subbranches, 486 descriptive statistics, 274 create a design, 411 dotplot, 274 data windows print options, 268 factorial design, 414 Design Custom Factorial Design, 412 fractional factorial design, 414–415 Design Custom Factorial Design—Low/High, gage R & R study, 142–143 412 gage run chart, 142 descriptive statistics, 275 histogram, 272 descriptive statistics—statistics, 275 individual value and moving range chart, dotplot–One Y, 274 461–462 dot plots, 274 interaction plot, 410 edit bars, 270 main effects plot, 409 Gage R & R study (crossed), 143 multivari chart, 191–192 Gage run chart, 142 normal distribution, 312 Histograms, 272 normal probability plot, 313 Histogram—Scale, 273 one-way ANOVA, 367 Histogram—Simple, 273 p-chart, 455 individual value and moving range chart, 462 5793Index.qxd_rf 6/11/04 3:00 PM Page 703

Index 703

Interactions Plot, 411 Nonprobability sample, 232, 692 Main Effects Plot, 410 Normal distribution, 15, 299–309, 692 Multi-Vari Chart, 192 tables of, 662–665 Multi-Vari Chart—options, 192 Normality assumption, 361 Normal distribution, 313 Normal probability plot, 138, 309–310, 324, 387, One Proportion, 330 394, 402, 406, 692 One Proportion—Options, 331 Nuisance variables, 172 One-Sample t, 329 Null event, 282 One-Sample t—options, 330 Null hypothesis, 334, 692 One-Way ANOVA, 368 One-Way ANOVA—graphs, 369 O One Way—Multiple Comparisons, 368 OK command button, 263 open worksheet, 262, 266 One-factor-at-a-time experiments, 195, 692 p-chart, 455 One-way analysis of variance, 353–359 p-chart—options, 456 One-way Kano category, 692 Pareto chart, 270 Operational definition, 104–107, 158–161, 235, Poisson distribution, 312 692 print worksheet, 262 Option button, 263 Probability Plot—Single, 314 Ordered array, 692 Probability Plot—Distribution, 314 Outliers, 692 run chart, 272 sample from columns, 277 P save worksheet, 267 p-chart, 429–433, 582, 614 test for equal variances, 369 p-value, 341, 692 Two Proportions, 364 Pareto chart, 201, 529, 567 Two Proportions—Options, 365 Pareto diagram, 236–238, 692 Two-Sample t, 365 Part-to-part variation, 108, 692 Two-Sample t—Graphs, 366 PDSA model, 35, 692, 693 Two-Sample t—Options, 366 Percent R & R, 110 Two Variances, 367 Percent tolerance, 693 Two-Way Analysis of Variance, 410 Pilot study, 208, 693 u-chart, 458 Point estimate, 319 X and R, 459 Poisson distribution, 297–299, 693 X and R—options, 459–460 Population, 230–231 X and S, 461 Post hoc, 359 Mission statement, 47, 691 Power of a statistical test, 339, 693 Mistake proofing, 208, 691 Prediction interval, 325–326, 693 Mode, 243, 247, 691 Proactive intervention, 693 Multiple comparisons, 359, 691 Probability, 280, 693 Multivari charts, 173, 175, 176, 691 Probability distribution, 286, 693 Must-be Kano category, 691 Probability sample, 233, 693 Mutually exclusive, 283, 692 Problem statement, 68 Process, 7, 693 N Process capability, 9 Natural limits, 129, 130, 692 Process improvement key objectives, 693 Noise variable, 173, 371, 692 Process owner, 31, 693 Nominal value, 11, 692 Process sigma, 32, 694 Nonadditive flag system, 692 Product-related data, 80, 694 5793Index.qxd_rf 6/11/04 3:00 PM Page 704

704 Index

Project charter, 66–67 Severity scale, 156, 695 Project objective, 73, 694 Shape, 253, 695 Project prioritization matrix, 57–59, 65, 694 Simple random sample, 233, 695 Project scope, 68–69, 694 SIPOC analysis, 74, 77, 500, 547, 606, 696 Projects, 51–52, 694 Six Sigma database, 696 Six Sigma management, 696 Q benefits, 7 Quality, 12 does it matter, 21–22 Quality control process chart, 221–222 key ingredients for success, 6 Quality project racking system, 92, 694 nontechnical definition, 14–15 Quartiles, 247–248, 694 prioritization of projects, 65 Questionable Kano category, 694 successful applications, 4–5 Quota sample, 232 technical definition, 15–22 R timeline, 5–6 Randomization, 173, 372, 694 what is new about, 22–23 Randomness assumption, 361 Skewness, 696 Range, 250, 694 Soft benefits, 70, 696 Region of nonrejection, 337 Special causes of variation, 419 Region of rejection, 337, 694 Special variation, 8, 696 Repeatability, 108, 694 Specification limits, 11–12, 130 Replicates, 197, 372, 694 Stability, 109, 696 Reproducibility, 108, 694 Standard deviation, 250–253, 696 Resolution, 110, 694 of a random variable, 289 Resolution III designs, 398, 694 Standard order, 383, 696 Resolution IV designs, 398, 694 Standard unit, 111, 696 Resolution V designs, 398, 694 Statistics, 230, 696 Response surface methodology designs, 195, 695 Stick-with-the-winner experiments, 195, 696 Reverse Kano category, 695 Strategic objectives, 696 Right-click, 260 Stratification, 476, 696 Right-skewed, 253 Stratified sample, 233, 696 Risk elements, 204, 695 Subjective approach to probability, 282 Risk management, 695 Summation notation, 245, 657–660 Risk priority number (RPN), 156, 695 Sum of Squares Among groups (SSA), 356, 372 Robust test, 695 Sum of Squares due to factor A (SSA), 198, 373, Rolled through yield (RTY), 32, 695 696 Run, 695 Sum of Squares due to factor B (SSB), 198, 373, Run chart, 126, 134, 136, 242, 610, 695 696 Sum of Squares due to interaction (SSAB), 198, S 373, 697 Sample, 230, 232, 316, 695 Sum of squares error (SSE), 198, 697 Sampling distribution, 316, 695 Sum of Squares total (SST), 198, 356, 372, 697 of the mean, 317–319 Sum of Squares Within groups (SSW), 356, 373 of the proportion, 319 Symmetrical, 253, 697 Sampling error, 321, 695 Systematic sample, 234, 697 Schedule, 695 Screening designs, 177, 194, 695 T SDSA model, 33–35, 695 t distribution, 697 Senior executive, 26, 695 tables of, 666–669 5793Index.qxd_rf 6/11/04 3:00 PM Page 705

Index 705

Taguchi loss function, 12–13, 592, 697 V Tampering, 420, 697 VA/NVA flowcharts, 148, 698 Tangible costs, 697 Variable, 235, 698 Tasks, 51–52, 697 Variables check sheet, 162–164, 698 Test for the difference between two means, Variable control charts, 418 pooled variance t test, 347–351 Variables process capability, 698 separate variance t test, 351–352 Variance, 250–253 Test for the difference between two proportions, Variation, 249, 698 342–346 Variation due to gages, 108 Test for the difference between two variances, Vision, 698 F test, 352–354 Voice of the customer, 11, 77, 698 Levene test, 354–355 relationship with voice of the process, 16–17 Test statistic, 697 Voice of the process, 7–11, 698 Tests of statistical significance, 334 relationship with voice of the customer, Tolerance, 697 16–17 Tollgate reviews, 697 analyze phase, 188–190 W control phase, 225–226 Window of opportunity, 40 define phase, 92–100 Windows, 260 improve phase, 214–215 opening programs, 261 measure phase, 140–141 Within-group variation, 355 Treatment effects, 355 Triangular cost distribution, 89, 697 X Tukey procedure, 359–360 ¯x and R charts, 127, 168, 169–172, 212, 440–444, Two-way ANOVA table, 117, 122 611 Two-factor factorial design, 197 ¯x and S charts, 444–448 Type I error, 338, 697 Type II error, 338, 697 Y U Yellow belt, 698 u-chart, 436–439 Yield, 698 Uncontrollable nuisance variable, 173, 697 Uniform cost distribution, 89, 697 Z Unit, 697 Zero project or task, 698 Upper specification limit, 698 Zone boundaries, 427 5793Index.qxd_rf 6/11/04 3:00 PM Page 706 5793Index.qxd_rf 6/11/04 3:00 PM Page 707 5793Index.qxd_rf 6/11/04 3:00 PM Page 708 5793Index.qxd_rf 6/11/04 3:00 PM Page 709 5793Index.qxd_rf 6/11/04 3:00 PM Page 710