This book offers a complete roadmap to conducting and executing Lean Six Sigma and Design for Six Sigma (DFSS) projects in service and transaction environments that are conducive to simulation modeling, including mapped tools, deliverables, and methods. Readers discover how Simulation–based Six Sigma methodology reduces project cycle time, cost, and effort from conception to validation. Most importantly, the Simulation–based Six Sigma design identifies customer and business requirements, conceptualizes several solutions, selects a vulnerability–free solution, optimizes that solution, and then validates and verifies the optimum solution, leading to breakthrough performance.
All the guidance needed to take advantage of the many tools in Simulation–based Six Sigma and Simulation–based DFSS is clearly set forth. The implementation, theoretical, and practical aspects of Six Sigma and DFSS and their associated toolboxes and methods are all set forth in detail, including:
- Integrating Voice of Customer and the Voice of the Business
- Axiomatic Design
- Design of Experiment
- Quality Function Deployment (QFD)
- Process Mapping
- Discrete Event Simulation (DES)
- Value Stream Mapping (VSM)
- Lean Techniques, including JIT, kanban, SMED, Kaizen, TPM, and more
This book is ideal as a reference for corporate executives, quality control managers, and service industry practitioners including manufacturing, Six Sigma belts and champions who want to streamline processes, minimize risk, and maximize benefits. It serves as a complete training manual for Six Sigma and DFSS in a simulation environment. With its many case examples, it is also a superior textbook for graduate students in management, operations, industrial engineering, and quality assurance.
PART I SIX–SIGMA FUNDAMENTALS.
1 Six–Sigma Fundamentals.
1.2 Quality and Six–Sigma Defined.
1.3 Introduction to Process Modeling.
1.4 Introduction to Business Process Management.
1.5 Measurement Systems Analysis.
1.6 Process Capability and Six–Sigma Process Performance.
1.7 Overview of Six–Sigma Improvement: DMAIC.
1.8 Six–Sigma Goes Upstream: Design for Six–Sigma.
2 Lean Six–Sigma Fundamentals.
2.2 Lean Six–Sigma Approach.
2.3 LSS–Enhanced DMAIC.
2.4 Lean Manufacturing.
2.5 Value Stream Mapping.
2.6 Lean Techniques.
3 Design for Six–Sigma Fundamentals.
3.2 Transaction–Based Design for Six–Sigma.
3.3 Service Design for Six–Sigma.
3.4 Service DFSS: The ICOV Process.
3.5 Service DFSS: The ICOV Process in Service Development.
PART II SIMULATION FUNDAMENTALS.
4 Basic Simulation Concepts.
4.2 System Modeling.
4.3 Simulation Modeling.
4.4 The Role of Simulation.
4.5 Simulation Software.
5 Discrete Event Simulation.
5.2 System Modeling with DES.
5.3 Elements of Discrete Event Simulation.
5.4 DES Mechanisms.
5.5 Manual Simulation Example.
5.6 Computer DES Example.
6 The Simulation Process.
6.2 Categories of Simulation Studies.
6.3 Systematic Simulation Approach.
6.4 Steps in a Simulation Study.
6.5 Example: Applying Simulation Process to a Hospital Emergency Room.
7 Simulation Analysis.
7.2 Terminating Versus Steady–State Simulation.
7.3 Determination of Simulation Run Controls.
7.4 Variability in Simulation Outputs.
7.5 Simulation–Based Optimization.
PART III SIMULATION–BASED SIX–SIGMA AND DESIGN FOR SIX–SIGMA.
8 Simulation–Based Six–Sigma Road Maps.
8.2 Lean Six–Sigma Process Overview.
8.3 Simulation–Based Lean Six–Sigma Road Map.
8.4 Simulation–Based Design for a Six–Sigma Road Map.
9 Simulation–Based Lean Six–Sigma Application.
9.2 3S–LSS Integrated Approach.
9.3 3S–LSS Case Study.
10 Simulation–Based Design for Six–Sigma Application.
10.2 3S–DFSS Process.
10.3 3S–DFSS Case Study: Dental Clinic Redesign.
11 Practical Guide to Successful Development of Simulation–Based Six–Sigma Projects.
11.2 Characteristics of a 3S Application.
11.3 Ingredients for a Successful 3S Program.
11.4 Framework for Successful 3S Implementation.
11.5 3S Project Charter.
11.6 3S Software Tools.
APPENDIX A BASIC STATISTICS.
APPENDIX B RANDOM NUMBERS.
APPENDIX C AXIOMATIC DESIGN.
APPENDIX D TAGUCHI’S QUALITY ENGINEERING.
APPENDIX E PROCESS MAPPING.
APPENDIX F VENDORS.
REFERENCES AND FURTHER READING.
RAID AL–AOMAR, PhD, is Assistant Professor of Industrial Engineering at Jordan University of Science and Technology (JUST). Dr. Al–Aomar has worked for several years as a consultant on Simulation and Lean Manufacturing at General Motors and Ford Motor Company in Detroit and as an adjunct faculty member at Wayne State University.