Abstract
This chapter examines how to engineer Six Sigma continuous improvement, design for Six Sigma (DFSS), and lean Six Sigma. Six Sigma process improvements consist of five different phases: phase 0—process definition/ project selection; phase I—process measurement; phase II—process analysis phase III—process improvement; and phase IV—process control and maintenance. The chapter presents the definitions and measurements of each of the phases. The statistical tools and methods involved in each phase are also illustrated. It is emphasized that thorough measurement of the existing process is necessary for redesign or future designs of process/product. The aspect of evaluation in each phase is also highlighted. Furthermore, it is stated that the process should be examined without any manipulation. The process engineer should identify independent variables (experimental factors) that affect dependent (response) variables in improving and contributing to the mean of normal distribution. Failure Mode Effects Analysis (FMEA) is an analytical approach for preventing defects by prioritizing potential problems and their resolution. Thorough analysis of the existing process is required for redesign in some cases or future designs of process/product. Process control requires a process and design control plan and team development, as well as statistical process control and advanced process control techniques.
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