Implementing Six Sigma: Smarter Solutions Using Statistical Methods: Second Edition / Edition 2

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Includes new and expanded coverage of Six Sigma infrastructure building and benchmarking. Provides plans, checklists, metrics, and pitfalls.

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Editorial Reviews

From Barnes & Noble
The Barnes & Noble Review
If you are involved in achieving bottom-line benefits and improved customer relationships for your organization, you don't want to miss this second edition of Implementing Six Sigma. This edition of the book takes the reader well beyond the traditional Six Sigma approach (consisting of six levels: knowledge, comprehension, application, analysis, synthesis, and evaluation) with an enhanced version that integrates other performance improvement techniques. Forrest W. Breyfogle calls this new approach Smarter Six Sigma Solutions (S4) Integrated Enterprise Excellence (IEE) or S4/IEE.

The book is divided into eight parts that cover S4/IEE, including measurement, analysis, implementation, control, integration, and management. For example, Part I describes the deployment of the S4/IEE implementation with a knowledge-centered activity (KCA) focus and the benefits. Parts II to V describe the measure-analyze-improve-control phases of define-measure-analyze-improve-control (DMAIC). Finally, parts VI to VIII describe other aspects for a successful S4/IEE implementation. Furthermore, this book is extremely thorough and well written, including an excellent set of exercises all along the way that provide a means of transforming information into virtual practical experience. John Vacca

John Vacca, the former computer security official (CSO) for NASA's space station program (Freedom), has written 38 books about advanced storage, computer security, and aerospace technology.

From the Publisher
"The book is process oriented rather than tool oriented. This makes it refreshing and useful. This is a book every reliability engineer should own." (Reliability Review; 12/08)

"An excellent reference book that should be on every individual involved in Six Sigma or even just quality assurance/quality improvement." (TQM Magazine)

"...a useful guide for both academia and organizations...useful source of reference for excellent reference book..." (The TQM Magazine, Vol 15(6) 2003)

From The Critics
"No other book covers-at an adequate technical level-as many topics important to Six Sigma. An indispensable reference for the Six Sigma practitioner."
Ramon V. Leon Associate Professor, Statistics Department of the University of Tennessee Associate editor, Six Sigma Forum magazine
"Implementing Six Sigma provides the most up-to-date material on the topic, complete with a project infrastructure roadmap and hundreds of real-life examples and exercises."
Frank Shines Project Manager, Pilgrim Software
John Wiley & Sons Publishing
A business initiative first espoused by Motorola in the early 1990s, the Six Sigma strategy has become a standard statistical technique for quality improvement. Breyfogle, founder and president of a quality consulting firm, explains the implementation of Six Sigma. The text is divided into five sections centered on using his "Smarter Six Sigma Solutions" -- deployment, measurement, analysis, improvement, and control -- and includes examples that describe the mechanics of implementation as well as application possibilities. Annotation c. Book News, Inc., Portland, OR (

"I have seen many Six Sigma approaches, but Breyfogle's Implementing Six Sigma is the most comprehensive of them all." --Frank Shines, Principal, IBM Global Services, Measurement Methods Consulting

"The key to business success is doing the right thing faster and better and more efficiently than your competition. The Six Sigma approach aims at achieving this and Forrest Breyfogle has written the most systematic and comprehensive manual available on the subject." --Paul Tobias, Manager, Statistical Methods Group, SEMATECH

"[This book] illustrates how most organizations can become more competitive, reduce defect levels, and improve cycle times. It consolidates not only the traditional Six Sigma process measurements and improvement tools, but also many other useful methodologies into one easy-to-understand text." --Bill Wiggenhorn, Senior Vice President of Motorola Training and Education; President, Motorola University

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Product Details

  • ISBN-13: 9780471265726
  • Publisher: Wiley
  • Publication date: 3/21/2003
  • Edition description: Second Edition
  • Edition number: 2
  • Pages: 1232
  • Sales rank: 628,941
  • Product dimensions: 6.18 (w) x 9.41 (h) x 2.33 (d)

Meet the Author

Forrest W. Breyfogle III is the founder and President of Smarter Solutions, Inc., a company specializing in training andconsulting in Six Sigma methodologies. He is the author of Statistical Methods for Testing, Development, and Manufacturing and Implementing Six Sigma and coauthor of Managing Six Sigma, all published by Wiley.

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Table of Contents



1. Six Sigma Overview and S4/IEEE Implementation.

2. Voice of the Customer and the S4/IEEE Define Phase.


3. Measurement and the S4/IEEE Measurement Phase.

4. Process Flow Charting/Process Mapping.

5. Basic Tools.

6. Probability.

7. Overview of Distributions and Statistical Processes.

8. Probability and Hazard Plotting.

9. Six Sigma Measurements.

10. Basic Control Charts.

11. Process Capability and Process Performance Metrics.

12. Measurement Systems Analysis.

13. Cause-and-Effect Matrix and Quality Function Deployment.

14. FMEA (Failure Mode and Effects Analysis).


15. Visualization of Data.

16. Confidence Intervals and Hypothesis Tests.

17. Inferences: Continuous Response.

18. Inference: Attribute (Pass/Fail) Response.

19. Comparison Tests: Continuous Response.

20. Comparison Tests: Attribute (Pass/Fail) Response.

21. Bootstrapping.

22. Variance Components.

23. Correlation and Simple Linear Regression.

24. Single-Factor (One-Way) Analysis of Variance (ANOVA) and Analysis of Means (ANOM).

25. Two-Factor (Two-Way) Analysis of Variance.

26. Multiple Regression, Logistic Regression, and Indicator Variables.


27. Benefiting from Design of Experiments (DOE).

28. Understanding the Creation of Full and Fractional Factorial 2K DOEs.

29. Planning 2K DOEs.

30. Design and Analysis of 2K DOEs.

31. Other DOE Considerations.

32. Robust DOE.

33. Response Surface Methodology.


34. Short-Run and Target Control Charts.

35. Control Charting Alternatives.

36. Exponentially Weighted Moving Average (EWMA) and Engineering Process Control (EPC).

37. Pre-Control Charts.

38. Control, Plan, Poka-Yoke, Realistic Tolerancing, and Project Completion.

39. Reliability Testing/Assessment: Overview.

40. Reliability Testing/Assessment: Repairable System.

41. Reliability Testing/Assessment: Nonrepairable Devices.

42. Pass/Fall Functional Testing.

43. S4/IEEE Application Examples.


44. Lean and Its Integration with S4/IEEE .

45. Integrating of Theory of Constraints (TOC) in S4 /IEE.


46. Manufacturing Applications and A 21-Step Integration of the Tools.

47. Service/Transactional Applications and A 21-Step Integration of the Tools.

48. DFSS Overview and Tools.

49. Product DFSS.

50. Process DFSS.


51. Change Management.

52. Project Management and Financial Analysis.

53. Team Effectiveness.

54. Creativity.

55. Alignment of Management Initiatives and Strategies with S4/IEEE .

Appendix A. Supplemental Information.

Appendix B. Equations for the Distributions.

Appendix C. Mathematical Relationships.

Appendix D. DOE Supplement.

Appendix E. Reference Tables.

List of Symbols.




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Implementing Six Sigma is a book for anyone who wants to make a difference in their organization. From the project manager or employee team member who just wants a step-by-step approach on what needs to be done during a Six Sigma project, to a highly trained quality engineer who needs a statistical reference manual or sample, real-life solutions to the most sophisticated testing, development and manufacturing problems, Implementing Six Sigma can meet the need. Let me tell you a true story to illustrate the point.

In September of 1993 I called the master of statistical methods, Dr. W. Edwards Deming to get his advice on a product quality problem I was trying to resolve for a major industrial motors manufacturer. I remember Deming asking me to speak louder as his hearing was beginning to fail him at the time. (As we all know, he passed away in his sleep at age 93 about two months later.) In classic Deming fashion, he chose his words wisely and carefully to give me the insight (not the answer) I needed to resolve this problem and then referred me to his latest book, The New Economics, for future reference. "I have distilled all that I have learned in this book," I recall him saying.

Coupling the insights I gained from that conversation with Deming with the practical methods of Forrest Breyfogle's Statistical Methods for Testing, Development, and Manufacturing, we (Forrest Breyfogle, Tom Common, Quality Engineer, and Dr. Pete Wung, R&D) were able to resolve-in a few weeks-an ineffective product quality process which had plagued the company for nearly seven years.

And now, Breyfogle has done it again with his latest books, Implementing Six Sigma. Here Breyfogle hascreated a practical and effective methodology, the S4 (Smarter Six Sigma Solutions) program, which guides the user through the process of:

  • Incorporating the organization's strategic vision into the aim of the Six Sigma project charter
  • Planning for and kicking off the project by attaining executive sponsorship and selecting the proper project team "champions"
  • Conducting executive, management and team education and training
  • Developing the proper organizational infrastructure and management and employee buy-in required to reduce resistance to change
  • Implementing the project charter using Measurement, Analysis, Improvement, and Control phases

I have seen many Six Sigma approaches, but Breyfogle's Smarter Six Sigma Solutions approach is the most comprehensive of them all. The S4 approach considers the importance of applying Six Sigma within a business context, by considering:

  • Organizational strategy and vision
  • A communications and education strategy
  • The corporate culture and history
  • Business economics and project prioritization
  • Organizational and individual skills and competencies
  • The pace and degree at which the organization can assimilate the change

In my experience working on projects throughout Europe and the Americas, whether for the military, industry or in the consulting profession, this is the finest collection of practical methods and sophisticated statistical problemsolving tools for today's real-life problems faced by those in both manufacturing and services.


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