Introduction:
This high impact program skillfully trains the participant to become a Lean Six-Sigma Green Belt professionals. This course enhances professional core competencies in World-Class business processes. Additionally, participants are better qualified to increase operational effectiveness, engage employees, reduce operating expenses, improve industry reputation, and leverage business excellence. Customer value creation awareness is a prime element of this unique training initiative.
Targeted Groups:
- Quality Assurance Professionals
- Managers, Supervisors, and Professionals who wish to fully utilize Six Sigma approach in their organizations
Course Objectives:
At the end of this course the participants will be able to:
- Enhance their understanding of the basic level Lean Six-Sigma process.
- Learn to successfully deploy Six-Sigma into current business operations for effectiveness through teamwork.
- Learn the basics of Lean Six-Sigma methodology, statistical analysis, and its analytical integration into the business process.
- Learn to integrate the principles of Lean Six-Sigma to establish process control and minimize process variation, subsequently, reducing operational costs.
- Develop their understanding of the skills and behaviors required to fully deploy Lean Six-Sigma into your organization.
- Understand how to deploy the potential of Lean Six-Sigma as a strategic business tool.
- Learn the basics of Lean Processing and Six-Sigma applications to focus on the reduction of operational costs.
- Learn to maximize profits by reducing process variation and expanding operational control and stability.
- Re-define their perception of “normal” to “excellent” with the skillful application of Lean Six-Sigma tools.
Targeted Competencies:
- Deploying Six Sigma
- Problem-solving skills
- Critical thinking skills
- Using applied statistics
- Lean principles
Course Content:
Unit 1: Understanding The Strategic Power of Six-Sigma Methodology:
- VOC, stakeholders & process owners, CTQ elements
- The basis of Six-Sigma; history and development; Understanding DMAIC process
- Strategic concepts & benefits of Benchmarking
- Six-Sigma deployment: DMAIC Concept
- Tollgate concept for Six-Sigma organizational functionality
- The power of data analysis in organization effectiveness and clarification
- Concepts of the Kano Analysis…three key elements of customer awareness
- Six Sigma in action. Project charters…Six-Sigma project integration
- The impact of lean process and Six Sigma, the perfect algorithm
- “Do It Yourself Six-Sigma” The application of Project Templates
- Defining Timelines and Deliverables…a clear project game plan
- The focus on value creation in business processes
- “Speed and Accuracy” Blending proven processing concepts
- Quality function deployment (QFD) for business operations
- Six Sigma as a Strategic Strategy and a Measurement of organizational quality
- Data-driven decision making…removing subjectivity in business decisions
- Key Metrics & Drivers for Organizational effectiveness market share
- World-Class Transformation to enhance competitiveness
- Kano analysis; three levels of customer responsiveness
Unit 2: Six-Sigma Deployment for Organization Effectiveness:
- Calculation: The costs of poor quality: COPQ; Understanding ROI
- Attribute and Continuous Data…recognizing the differences for application
- Descriptive and Inferential statistics…knowing when to use what
- Histograms. Measures of central tendency…normal statistical distributions
- Normal Distributions, Standard Scores, Z tables
- Student’s t-Tests, statistical degrees of freedom
- Process Capability - voice of the process; central tendency of the data set
- Statistical Mean, Median & Mode; Calculation of Sigma Failure Rates; DPMO
- Microsoft Excel & Minitab Statistical Software Applications
- Process Base Line; Data Collection Plan
- Y= f x - Matrix; Identification of KPIV
- Graphing Discrete & Continuous Data; software interface
- Graphing Discrete & Continuous Data; software interface
- Population & Sample data
- Central Limit Theorem, confidence intervals
- Hypothesis Testing for the mean, Type I & Type II Errors, alpha risks
- Process Capability
- Process Tolerance, Measures of Dispersion, central tendency, Cp & Cpk,
- Statistical (natural process) Limits & Customer Specification Limits: LCL & UCL
- Bivariate data analysis in Six-Sigma applications
- Gauge R&R; Measurement Systems Analysis (MSA)
Unit 3: Concepts of Lean Processing:
- History of Lean Manufacturing
- Lean Analysis: transformation from current state to future state
- Cycle Time Compression; improving process throughput
- Supply Chain Acceleration
- Value Stream Mapping; focus on value creation: value chain identification
- Muda: Identifying Seven Types of Wastes
- Muri: Work complexity & fatigue factors
- Mura: Focus on Process Flow; Roll Throughput Yield RTY
- 5S concepts for workplace organization & effectiveness
- Visual controls, Poka Yoke concept; prevention/detection/mitigation
- SMED Concepts to speed up processes
- Team dynamics, Team conflict: (forming, storming, norming, performing)
- SIPOC Diagrams; three levels of Process maps, flowcharts
Unit 4: Blending Lean Principles in Business Processes:
- Standardized Work Applications to maximize efficiency and reduce variation
- Batch & Queue VS Single element processing
- Kanban Inventory operational systems
- Understanding the Theory of Constraints
- Total Productive Maintenance (TPM ) for operational costs reduction
- The effective integration of RFID/bar codes
- Employee Empowerment for organizational effectiveness/Kaizen interface *
- Point of Use Supply
- Quality at the Source
- Green Process Integration
- Six-Sigma project work/team dynamics and interaction
- Cause & Effect Diagrams: Ishikawa/fishbone chart Analysis
- FMEA Matrix applications for Six-Sigma; calculating the RPN
- Production Balance: The Importance of TAKT Time Awareness
- Project tools: Gantt charts, critical path method (CPM) & PERT evaluation
- Brainstorming for Results, Pareto Analysis 80/20 Analysis*
- Improving the Process for effectiveness; Lean process & Six-Sigma Integration
- High-level Green Analysis
- Ishikawa Diagrams, Brainstorming, Pareto 80/20
- Brainstorm for Project Benefits…integration of team dynamics: the Five whys
Unit 5: Skillfully Applying the Tools of Six-Sigma for Success:
- Tools to speed analysis…finding the root cause of variation
- Measuring and tracking improvement; Establishing Process Baseline
- Hold the line... standardization/optimization
- Tools to prioritize improvement opportunities
- Successful ways to define and mitigate failure modes
- FMEA Diagrams in Action…how to identify process trouble spots
- Project Closure; Control plans that WORK!
- Continued workplace training...SOP for succession planning for success;
- Innovative Six-Sigma deployment opportunities
- SPC; Monitoring Systems, Locking the Learning
- Control Chart Utilization; Juran, Deming, & Shewhart
