Simulation-based Lean Six-Sigma and Design for Six-Sigma

BASEM EL-HAIK, PhD, is a Six Sigma and Design for Six Sigma consultant, author, and founder of Six Sigma Professionals, Inc., a firm providing Six Sigma and DFSS implementation, training, and consulting for industries ranging from financial services to high technology. Dr. El-Haik is a well-known author, consultant, and speaker on the subject. Throughout his career Dr. El-Haik trained, certified, coached, and mentored over 400 belts (Green Belts, Black Belts, and Master Black Belts) in DFSS and Six Sigma in both tracks: product and service (transactional). 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.

• PREFACE. PART I SIX-SIGMA FUNDAMENTALS.1 Six-Sigma Fundamentals.1.1 Introduction.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.1.9 Summary.2 Lean Six-Sigma Fundamentals.2.1 Introduction.2.2 Lean Six-Sigma Approach.2.3 LSS-Enhanced DMAIC.2.4 Lean Manufacturing.2.5 Value Stream Mapping.2.6 Lean Techniques.2.7 Summary.3 Design for Six-Sigma Fundamentals.3.1 Introduction.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.3.6 Summary.PART II SIMULATION FUNDAMENTALS.4 Basic Simulation Concepts.4.1 Introduction.4.2 System Modeling.4.3 Simulation Modeling.4.4 The Role of Simulation.4.5 Simulation Software.4.6 Summary.5 Discrete Event Simulation.5.1 Introduction.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.5.7 Summary.6 The Simulation Process.6.1 Introduction.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.6.6 Summary.7 Simulation Analysis.7.1 Introduction.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.8.1 Introduction.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.8.5 Summary.9 Simulation-Based Lean Six-Sigma Application.9.1 Introduction.9.2 3S-LSS Integrated Approach.9.3 3S-LSS Case Study.9.4 Summary.10 Simulation-Based Design for Six-Sigma Application.10.1 Introduction.10.2 3S-DFSS Process.10.3 3S-DFSS Case Study: Dental Clinic Redesign.10.4 Summary.11 Practical Guide to Successful Development of Simulation-Based Six-Sigma Projects.11.1 Introduction.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.INDEX.