The Green Six Sigma Handbook

The Green Six Sigma Handbook

by Ron Basu
Released September 2022
Publisher(s): Productivity Press
ISBN: 9781000648003

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Book description

This book is a hands-on single-source reference of tools, techniques, and processes integrating both Lean and Six Sigma. This comprehensive handbook provides up-to-date guidance on how to use these tools and processes in different settings, such as start-up companies and stalled projects, as well as establish enterprises where the ongoing drive is to improve processes, profitability, and long-term growth. It contains the "hard" Six Sigma approach as well as the flexible approach of FIT SIGMA, which is adaptable to manufacturing and service industries and also public sector organisations. You will also discover how climate change initiatives can be accelerated to sustainable outcomes by the holistic approach of Green Six Sigma.

The book is about what we can do now with leadership, training, and teamwork in every sphere of our businesses. Lean, originally developed by Toyota, is a set of processes and tools aimed at minimising wastes. Six Sigma provides a set of data-driven techniques to minimise defects and improve processes. Integrating these two approaches provides a comprehensive and proven approach that can transform an organisation. To make change happen, we need both digital tools and analog approaches. We know that there has been a continuous push to generate newer approaches to operational excellence, such as Total Quality Management, Six Sigma, Lean Sigma, Lean Six Sigma, and FIT SIGMA.

It is vital that we harness all our tools and resources to regenerate the economy after the Covid-19 pandemic and make climate change initiatives successful for the survival of our planet. Six Sigma and its hybrids (e.g., Lean Six Sigma) should also play a significant part. Over the last three decades, operational performance levels of both public sector and private sector organisations improved significantly and Lean Six Sigma has also acted as a powerful change agent. We urgently need an updated version of these tools and approaches.

The Green Six Sigma Handbook not only applies appropriate Lean and Six Sigma tools and approaches, fitness for the purpose, but it aims at sustainable changes. This goal of sustainability is a stable bridge between Lean Six Sigma and climate change initiatives. Hence, when the tools and approaches of Lean Six Sigma are focused and adapted primarily to climate change demands, we get Green Six Sigma.

Table of contents

  1. Cover
  2. Half Title
  3. Title
  4. Copyright
  5. Dedication
  6. Contents
  7. Foreword
  8. Preface
  9. Acknowledgements
  10. About the Author
  11. Part I Foundations of Six Sigma and Lean
    1. 1 Quality and Operational Excellence
      1. 1.1 Introduction
      2. 1.2 Tools and Techniques
        1. 1.2.1 Tools and Techniques
      3. 1.3 What Is Quality?
      4. 1.4 Hierarchy of Quality
      5. 1.5 Cost of Quality
      6. 1.6 Quality Movement
      7. 1.7 W Edwards Deming
      8. 1.8 Joseph M Juran
      9. 1.9 Armand V Feigenbaum
      10. 1.10 Philip B Crosby
      11. 1.11 What of the Japanese?
      12. 1.12 Lean Enterprise
      13. 1.13 Total Productive Maintenance
      14. 1.14 ISO 9000
      15. 1.15 Kaizen
      16. 1.16 Quality Circles
      17. 1.17 Summary
    2. 2 The Evolution of Six Sigma, Lean Six Sigma and Green Six Sigma
      1. 2.1 Introduction
      2. 2.2 First Wave: As Is to TQM
      3. 2.3 Second Wave: TQM to Lean Six Sigma
      4. 2.4 Third Wave: Lean Six Sigma to FIT SIGMA and Green Six Sigma
      5. 2.5 More about Six Sigma
      6. 2.6 What Is Six Sigma?
      7. 2.7 The Structured Approach of Six Sigma
      8. 2.8 Certification of Black Belts and Master Black Belts
      9. 2.9 What Is Lean Six Sigma?
        1. 2.9.1 Elimination of Waste
        2. 2.9.2 Smooth Operational Flow
        3. 2.9.3 High Level of Efficiency
        4. 2.9.4 Quality Assurance
      10. 2.10 More on Lean Six Sigma
      11. 2.11 Why FIT SIGMA?
      12. 2.12 What Is Green Six Sigma?
      13. 2.13 Summary
    3. 3 More of Green Six Sigma
      1. 3.1 Introduction
      2. 3.2 Fitness for Purpose
      3. 3.3 Sigma (Σ) for Improvement and Integration
        1. 3.3.1 The Appropriate Green Six Sigma Tools
        2. 3.3.2 Appropriate DMAIC Methodology
        3. 3.3.3 Learning Deployment
        4. 3.3.4 Project Plan and Delivery
        5. 3.3.5 Shift from Variation (σ) to Integration (Σ)
      4. 3.4 Fitness for Sustainability
        1. 3.4.1 Performance Management
        2. 3.4.2 Sales and Operations Planning (S&OP)
        3. 3.4.3 Self-Assessment and Certification
        4. 3.4.4 Knowledge Management
      5. 3.5 Summary
    4. 4 Managing Green Six Sigma Projects with DMAICS
      1. 4.1 Introduction
      2. 4.2 Definition
      3. 4.3 Define Phase
      4. 4.4 Measure Phase
      5. 4.5 Analyse Phase
      6. 4.6 Improve Phase
      7. 4.7 Control Phase
      8. 4.8 Sustain Phase
      9. 4.9 Application
        1. 4.9.1 Basic Steps
        2. 4.9.2 Worked-Out Example
        3. 4.9.3 Define
        4. 4.9.4 Measure
        5. 4.9.5 Analyse
        6. 4.9.6 Improve
        7. 4.9.7 Control
        8. 4.9.8 Sustain
        9. 4.9.9 Benefits
        10. 4.9.10 Pitfalls
        11. 4.9.11 Training Requirements
      10. 4.10 DMAICS and DMADV
        1. 4.10.1 Define
        2. 4.10.2 Measure
        3. 4.10.3 Analyse
        4. 4.10.4 Design
        5. 4.10.5 Verify
      11. 4.11 Summary
    5. 5 The Scope of Green Six Sigma Tools and Techniques
      1. 5.1 Introduction
      2. 5.2 The Drivers for Tools and Techniques
      3. 5.3 The Problems of Using Tools and Techniques
        1. 5.3.1 Inadequate Training
        2. 5.3.2 Management Commitment of Resources
        3. 5.3.3 Employee Mindset
        4. 5.3.4 Poor Application of Tools and Techniques
      4. 5.4 The Critical Success Factors
        1. 5.4.1 Top Management Commitment
        2. 5.4.2 Availability of Resources
        3. 5.4.3 Well-Designed Education and Training Programme
        4. 5.4.4 Rigorous Project Management Approach
      5. 5.5 Summary
    6. 6 The Digital Revolution and Climate Change
      1. 6.1 Introduction
      2. 6.2 Information Technology and Systems
        1. 6.2.1 IT Hardware Strategy
        2. 6.2.2 IT Software Strategy
        3. 6.2.3 Market-Making Applications
        4. 6.2.4 Enterprise Resource Planning Applications
        5. 6.2.5 Customer Relationships Management Solutions
        6. 6.2.6 Supply Chain Management Solutions
        7. 6.2.7 Implementation Strategy
      3. 6.3 E-business
        1. 6.3.1 E-commerce Solutions
      4. 6.4 Big Data and Artificial Intelligence
      5. 6.5 Digital Tools for Green Six Sigma
      6. 6.6 Quality 4.0
      7. 6.7 Digital Technology Applications in Climate Change
      8. 6.8 Summary
    7. 7 Green Six Sigma in Manufacturing, Services, Projects and SMEs
      1. 7.1 Introduction
      2. 7.2 Green Six Sigma in Large Manufacturing Operations
      3. 7.3 Green Six Sigma in Service Operations
      4. 7.4 Green Six Sigma in Project Management
      5. 7.5 Green Six Sigma in Small and Medium-Sized Enterprises
      6. 7.6 Summary
  12. Part II Tools for Green Six Sigma
    1. 8 Tools for Definition
      1. 8.1 Introduction
      2. 8.2 Description of Tools for Definition
        1. 8.2.1 D1: IPO Diagram
        2. 8.2.2 D2: SIPOC Diagram
        3. 8.2.3 D3: Flow Diagram
        4. 8.2.4 D4: Critical to Quality Tree
        5. 8.2.5 D5: Project Charter
      3. 8.3 Summary
    2. 9 Tools for Measurement
      1. 9.1 Introduction
      2. 9.2 Description of Tools for Measurement
        1. 9.2.1 M1: Check Sheets
        2. 9.2.2 M2: Histograms
        3. 9.2.3 M3: Run Charts
        4. 9.2.4 M4: Scatter Diagrams
        5. 9.2.5 M5: Cause and Effect Diagrams
        6. 9.2.6 M6: Pareto Charts
        7. 9.2.7 M7: Control Charts
        8. 9.2.8 M8: Flow Process Charts
        9. 9.2.9 M9: Process Capability Measurement
      3. 9.3 Summary
    3. 10 Tools for Analysis
      1. 10.1 Introduction
      2. 10.2 Description of Tools for Analysis
        1. 10.2.1 A1: Process Mapping
        2. 10.2.2 A2: Regression Analysis
        3. 10.2.3 A3: RU/CS Analysis
        4. 10.2.4 A4: SWOT Analysis
        5. 10.2.5 A5: PESTLE Analysis
        6. 10.2.6 A6: The Five Whys
        7. 10.2.7 A7: Interrelationship Diagram
        8. 10.2.8 A8: Overall Equipment Effectiveness
        9. 10.2.9 A9: Tree Diagram
      3. 10.3 Summary
    4. 11 Tools for Improvement
      1. 11.1 Introduction
      2. 11.2 Description of Tools for Improvement
        1. 11.2.1 I1: Affinity Diagram
        2. 11.2.2 I2: Nominal Group Technique
        3. 11.2.3 I3: SMED
        4. 11.2.4 I4: Five S’s
        5. 11.2.5 I5: Mistake Proofing
        6. 11.2.6 I6: Value Stream Mapping
        7. 11.2.7 I7: Brainstorming
        8. 11.2.8 I8: Mind Mapping
        9. 11.2.9 I9: Force Field Analysis
      3. 11.3 Summary
    5. 12 Tools for Control
      1. 12.1 Introduction
      2. 12.2 Description of Tools for Control
        1. 12.2.1 C1: Gantt Chart
        2. 12.2.2 C2: Activity Network Diagram
        3. 12.2.3 C3: Radar Chart
        4. 12.2.4 C4: The PDCA Cycle
        5. 12.2.5 C5: Milestone Tracker Diagram
        6. 12.2.6 C6: Earned Value Management
      3. 12.3 Summary
    6. 13 Tools for Sustainability
      1. 13.1 Introduction
      2. 13.2 Description of Tools for Sustainability
        1. 13.2.1 S1. Material Flow Analysis
        2. 13.2.2 S2. Carbon Footprint Tool
      3. 13.3 Summary
  13. Part III Techniques for Green Six Sigma
    1. 14 Quantitative Techniques
      1. 14.1 Introduction
      2. 14.2 Selection of Techniques
      3. 14.3 Structure of Presentation
        1. 14.3.1 Q1: Failure Mode and Effects Analysis
        2. 14.3.2 Q2: Statistical Process Control
        3. 14.3.3 Q3: Quality Function Deployment
        4. 14.3.4 Q4: Design of Experiments
        5. 14.3.5 Q5: Design for Six Sigma
        6. 14.3.6 Q6: Monte Carlo Technique
        7. 14.3.7 Q7: TRIZ: Inventive Problem-Solving
        8. 14.3.8 Q8: Measurement System Analysis
      4. 14.4 Summary
    2. 15 Qualitative Techniques
      1. 15.1 Introduction
      2. 15.2 Description of Qualitative Techniques
        1. 15.2.1 R1: Benchmarking
        2. 15.2.2 R2: The Balanced Scorecard
        3. 15.2.3 R3: European Foundation of Quality Management
        4. 15.2.4 R4: Sales and Operations Planning
        5. 15.2.5 R5: Knowledge Management
        6. 15.2.6 R6: Kanban
        7. 15.2.7 R7: Activity-Based Costing
        8. 15.2.8 R8: Quality Management Systems (ISO 9000)
        9. 15.2.9 R9: Kaizen
      3. 15.3 Summary
  14. Part IV Green Six Sigma and Climate Change
    1. 16 Climate Change Challenges
      1. 16.1 Introduction
      2. 16.2 The Earth’s Temperature Is Rising
      3. 16.3 Greenhouse Gas Emissions by Country
      4. 16.4 Greenhouse Gas Emissions by Economic Sector
      5. 16.5 Summary
    2. 17 International and National Climate Change Initiatives
      1. 17.1 Introduction
      2. 17.2 International Climate Change Initiatives
        1. 17.2.1 The United Nations Framework Convention on Climate Change
        2. 17.2.2 The Kyoto Protocol
        3. 17.2.3 International Carbon Action Partnership
        4. 17.2.4 The Paris Climate Agreement
        5. 17.2.5 The Conference of Parties
        6. 17.2.6 The Intergovernmental Panel on Climate Change
        7. 17.2.7 Other International Initiatives
      3. 17.3 National Climate Change Initiatives
        1. 17.3.1 European Union Emissions Trading System
        2. 17.3.2 UK Climate Change Initiatives
        3. 17.3.3 US Climate Change Initiatives
        4. 17.3.4 China Climate Change Initiatives
        5. 17.3.5 India Climate Change Initiatives
        6. 17.3.6 Russia Climate Change Initiatives
        7. 17.3.7 Japan Climate Change Initiatives
      4. 17.4 Summary
    3. 18 Green Six Sigma and Clean Energy
      1. 18.1 Introduction
      2. 18.2 Guiding Factors of Clean Energy
      3. 18.3 How Clean Energy Solutions Can Reduce Greenhouse Gas Emissions
      4. 18.4 How Six Sigma Is Helping Clean Energy Initiatives
      5. 18.5 How Green Six Sigma Can Help Clean Energy Initiatives Further
      6. 18.6 Summary
    4. 19 Green Six Sigma and Green Supply Chain
      1. 19.1 Introduction
      2. 19.2 Green Thinking and Climate Change Initiatives
      3. 19.3 Why Green Six Sigma Is Relevant to Green Supply Chain
      4. 19.4 Green Initiatives by Manufacturers and Suppliers
      5. 19.5 Green Initiatives by Retailers
      6. 19.6 Green Initiatives by Consumers
      7. 19.7 Green Initiatives by Farmers
      8. 19.8 How Green Six Sigma Can Help Green Supply Chain
        1. 19.8.1 FIT SIGMA in Efficiency
        2. 19.8.2 Green Six Sigma in the Environment
        3. 19.8.3 Green Six Sigma in Ethics
      9. 19.9 Summary
    5. 20 Green Six Sigma and Green Transports
      1. 20.1 Introduction
      2. 20.2 Guiding Factors of Clean Transports
      3. 20.3 How Clean Transport Solutions Reduce Greenhouse Gas Emissions
        1. 20.3.1 Passenger Cars
        2. 20.3.2 Trucks and Buses
        3. 20.3.3 Airplanes and Ships
        4. 20.3.4 Trains
      4. 20.4 How Six Sigma Is Helping Green Transport Initiatives
      5. 20.5 How Green Six Sigma Can Help Green Transport Initiatives Further
      6. 20.6 Summary
    6. 21 Green Six Sigma and Retrofitting Buildings
      1. 21.1 Introduction
      2. 21.2 Guiding Factors of Retrofitting Buildings
      3. 21.3 How Retrofitting Buildings Provides Solutions for Reducing Greenhouse Gas Emissions
        1. 21.3.1 Reduce Energy Losses and Energy Consumption
        2. 21.3.2 Replace Fossil Fuel Boilers and Water Heaters
        3. 21.3.3 Seek to Use Renewable Energy
        4. 21.3.4 Apply a Circular Economy
      4. 21.4 How Six Sigma Is Helping Retrofitting Buildings Initiatives
      5. 21.5 How Green Six Sigma Can Help Retrofitting Houses Initiatives Further
      6. 21.6 Summary
    7. 22 Green Six Sigma and Climate Adaptation
      1. 22.1 Introduction
      2. 22.2 Climate Adaptation in the Global Community
        1. 22.2.1 How Green Six Sigma Can Help
      3. 22.3 Climate Adaptation in Clean Energy
        1. 22.3.1 How Green Six Sigma Can Help
      4. 22.4 Climate Adaptation in Green Supply Chains
        1. 22.4.1 How Green Six Sigma Can Help
      5. 22.5 Climate Adaptation in Green Transports
        1. 22.5.1 How Green Six Sigma Can Help
      6. 22.6 Climate Adaptation in Retrofitting Houses
        1. 22.6.1 How Green Six Sigma Can Help
      7. 22.7 Climate Adaptation and Infra-Structure Projects
        1. 22.7.1 How Green Six Sigma Can Help
      8. 22.8 Climate Adaptation and Innovation
        1. 22.8.1 How Green Six Sigma Can Help
      9. 22.9 Summary
  15. Part V Implementation of Green Six Sigma
    1. 23 Case Studies
      1. 23.1 Introduction
      2. 23.2 Case Example for Large Manufacturing Organisations
      3. 23.3 Case Examples for Services, SMEs and Projects
      4. 23.4 How Green Six Sigma Could Help More
      5. 23.5 Summary
    2. 24 Implementation: Making it Happen
      1. 24.1 Introduction
      2. 24.2 Implementation of Climate Change Initiatives
        1. 24.2.1 International Community
        2. 24.2.2 National and Local Governments
        3. 24.2.3 Non-Governmental Organisations
        4. 24.2.4 Industry and Service Providers
        5. 24.2.5 The General Public
        6. 24.2.6 Media
        7. 24.2.7 A New Measure of Sustainability
        8. 24.2.8 Practitioners
      3. 24.3 The Implementation of Green Six Sigma
      4. 24.4 Implementation for New Starters
        1. 24.4.1 Step One: Management Awareness
        2. 24.4.2 Step Two: Initial Assessment
        3. 24.4.3 Step Three: Programme Brief and Organisation
        4. 24.4.4 Step Four: Leadership Workshop
        5. 24.4.5 Step Five: Training Deployment
        6. 24.4.6 Step Six: Project Selection and Delivery
        7. 24.4.7 Step Seven: Measurement of Success
        8. 24.4.8 Step Eight: Culture Change and Sustainability
        9. 24.4.9 Step Nine: Improve and Sustain
      5. 24.5 Green Six Sigma for ‘Stalled’ Six Sigma
      6. 24.6 Green Six Sigma for Small and Medium-Sized Enterprises
      7. 24.7 Green Six Sigma for Successful Organisations
      8. 24.8 External Consultants
      9. 24.9 Summary
    3. 25 Afterword
      1. 25.1 Introduction
      2. 25.2 Side Deals
      3. 25.3 Analysis
  16. Appendices
  17. Glossary
  18. References
  19. Index

Product information

  • Title: The Green Six Sigma Handbook
  • Author(s): Ron Basu
  • Release date: September 2022
  • Publisher(s): Productivity Press
  • ISBN: 9781000648003