After completing this course, you should be able to DO the following:

        • Communicate using Lean Six Sigma concepts.

        • Think about your organization as a collection of processes, with inputs that determine the output.

        • Relate Six Sigma concepts to the overall business mission and objectives.

        • Use the concept of a Sigma Level to Evaluate the capability of a process or organization.

        • Understand and apply the five step D-M-A-I-C model as a framework to    organize process improvement activity.

        • Employ a wide range of continuous process improvement techniques within the D-M-A-I-C model.

        • Recognize the organizational factors that are necessary groundwork for a successful Lean Six Sigma effort.

        • Employ your Lean Six Sigma skills to lead a successful process improvement project to Deliver meaningful results to the organization. 

Course Content and Outline

Total Estimated Hours: 93.4

1. Introduction to Six Sigma (4.7 Hours)

• Higher Standards for Higher Performance

• Input Determines Output

• Six Sigma Defined

• Success Stories

• The Sigma Level

• The 99.9% Problem

• Calculating the Sigma Level - Toolset

• DNA of a Champion

• Six Sigma Framework

• DMAIC - The Six Sigma Improvement Process

• Lean and DMAIC

• Thought Process Mapping - Toolset

• Organizing for Success

• Working Relationships

• Critical Success Factors

• What's In a Name?

• Exercises and Quiz

2. Define I - The Value Stream (7.7 Hours)

• Introduction to Define

• Process Thinking

• The Source of Value

• Value Stream Leverage

• Process Mapping - Overview

• Process Mapping (SIPOC)Toolset

• Flow Charts

• Value-Added Flow Charts

• Spaghetti Charts

• Value Stream Mapping Toolset

• Pareto Chart Toolset

• Project Selection Toolset

• Project Charter Toolset

• Project Tracking Toolset

• Exercises and Quiz

3. Define II - Voice of the Customer (7.4 Hours)

• Introduction to Voice Of The Customer

• Focus on The Customer

• Understanding Customer Requirements

• Where to Go For Customer Requirements

• Conducting Surveys

• More on Surveys

• Surveys - Sampling Frame

• Structuring Survey Questions

• The Degree of Uncertainty in Sampling

• Guideline for Margin of Error

• Affinity Diagram Toolset

• CTQC Tree Diagram Toolset

• Operational Definition Toolset

• Voice Of The Customer As Specifications

• Progress Review

• Exercises and Quiz

4. Measure I (9.9 Hours)

• Introduction to Measure

• Measurements

• Discrete vs. Continuous Measurements

• Measurement Subjects

• Measurement As A Process

• The Analysis of Measurement Systems

• The Requirements of Measurement Systems

• Gage R & R

• MSA - Graphing

• Attribute Measurement System Analysis

• Calibration of Measurement Systems

• Collecting Data

• Developing a Sampling Plan

• Baseline Performance

• Derivative Performance Metrics - Throughput Yield

• Derivative Performance Metrics - Rolled Throughput Yield

• The Sigma Level Revisited

• Exercises and Quiz 

• 5. Measure II - Charting Process Behavior (12.4 Hours)

  • Introduction - Measure II

  • Trend Chart Toolset

  • Histogram Toolset

  • Quantifying Process Variability

  • SPC - Introduction and Background

  • SPC - Introduction to Control Charts

  • SPC - Control Chart Limits

  • SPC - More On Control Limits

  • Implementing SPC

  • SPC Chart Selection

  • Rational Subgrouping Toolset

  • X and Moving Range Charts - Toolset

  • Attribute Control Chart Toolset

  • X-bar and R Chart Toolset

  • Related Theory

  • Process Capability Toolset

  • Progress Review

  • Exercises and Quiz

   

   

  6. Analyze I - Possible Root Cause (10.2 Hours)

  • Introduction to Analyze

  • Finding The Root Cause

  • Cause & Effect Diagram Toolset

  • Alternative To The Cause & Effect Diagram

  • 5-Why, 1-How

  • A Combination of 5-Why, Pareto, and Trend Charts

  • Scatter Plot Toolset

  • Correlation and Regression Analysis

  • Multiple Regression Toolset

  • Logistic Regression Toolset

  • Factors In Determining Sample Size

  • Estimating Population Mean

  • Exercises and Quiz

   

   

  7. Analyze II - Hypothesis Testing (13.3 Hours)

  • Introduction to Analyze II

  • Introduction to Hypothesis Testing

  • The Process On Trial

  • The Hypothesis - Accept or Reject?

  • Types of Error

  • Hypothesis Testing

  • Confidence Intervals

  • Treatment Comparisons - Control Charts

  • Comparing Two Proportions - Z-test Toolse

  • Comparing Two Means - t-test Toolset

  • Comparing Multiple Means - ANOVA /F-test Toolset

  • Comparing Two Variances - F-test Toolset

  • Confidence Intervals - Least Significant Difference

  • Hypothesis Testing Learning Lab

  • Exercises and Quiz

   

   

  8. Analyze III – DOE (5.8 Hours)

  • Design of Experiments - Introduction

  • Design of Experiments

  • Design of Experiments - Components

  • Design of Experiments - Purpose

  • Design of Experiments - Process

  • Blocking

  • Blocking and Tackling

  • Progress Review

  • Exercises and Quiz 

   

  9. Improve (10.7 Hours)

  • Introduction to Improve

  • Design for Six Sigma (DFSS)

  • Benchmarking

  • Brainstorming

  • Narrowing Down The List of Ideas

  • FMEA Toolset

  • Error-proofing

  • Continuous Flow Toolset

  • Quick Changeover Toolset

  • Pull Scheduling

  • Prioritizing and Selecting a Solution

  • Corrective Action Matrix

  • Piloting a Solution

  • System Dynamics

  • Characteristics of Dynamic Systems

  • System Dynamics Examples

  • Another System Dynamics Example

  • System Dynamics Application

  • System Dynamics Summary

  • Progress Review

  • Exercises and Quiz

   

  10. Control (6.5 Hours)

  • Introduction to Control

  • More On SPC

  • The Process Control Plan

  • More On FMEA

  • Visual Control

  • 5-S Approach

  • Total Productive Maintenance

  • TPM Objectives & Benefits

  • TPM Metrics

  • TPM Core Elements

  • TPM Maintenance Activities

  • Best Practices and Lessons Learned

  • Documenting Process Changes

  • Ending the Project

  • Progress Review

  • Exercises and Quiz

   

   

  11. Leading Teams and Leading Change (4.8 Hours)

  • Leadership Introduction

  • Fueling The Improvement Engine

  • Leadership Characteristics

  • Practice, Study and Reflection - Learning by Modeling

  • Leading Teams

  • Developing an Effective Team

  • Improving Team Development

  • Leading Change

  • Leading Change - Continued

  • Success Factors For Effective Change Management

  • Exercises and Quiz

  • Course Completion

       • The Lean Six Sigma Journey