Six Sigma (Green Belt)

COURSE OUTLINES

Why Do Six Sigma

  1. Definition and graphical view of Six Sigma.
  2. Comparisons between typical TQM and Six Sigma Programs.
  3. Origins and Success Stories.

How to Deploy Six Sigma

  1. Leadership responsibilities
  2. Description of the roles and responsibilities
  3. Resource allocation
  4. Data driven decision making
  5. Organizational metrics and dashboards

Six Sigma Projects

  1. Project Focus
  2. Selecting Projects
  3. Overview of DMAIC methodology
  4. Project Reporting

DEFINE: Project Definition

  1. Tasks.
  2. Project Charters.
  3. Work Breakdown Structure.
  4. Pareto Diagrams.
  5. Process Maps.
  6. SIPOC.
  7. Reporting.

DEFINE: Metrics & Deliverables

  1. CTC, CTQ, CTS Parameters
  2. CTx Flow-down Model (Big Y's, Little y's)
  3. Measurement & Feedback
  4. Throughput Yield, DPMO, Sigma Level Calculations
  5. Process Cycle Efficiency, Lead Time, Velocity, OEE Calculations.

DEFINE: Project Scheduling

  1. Critical Path Analysis / Activity Network Diagram.
  2. PERT Analysis.
  3. GANNT Chart.

DEFINE: Change Management and Six Sigma Teams

  1. Problems with Change
  2. Achieving Buy-In
  3. Team Formation, Rules & Responsibilities
  4. Consensus Building

MEASURE: Tools

  1. Measure Stage Objectives
  2. Process Definition (Flowcharts, Process Maps)
  3. Metric Definition.
  4. Enumerative vs. Analytic Statistics.
  5. Process Variation (Deming's Red Bead)
  6. Benefits of Control Charts.
  7. Requirements vs. Control (Tampering)
  8. Control Chart as Process Baseline Tool.

MEASURE: X-Bar Charts

  1. Uses / Assumptions
  2. Construction & Calculations.
  3. Rational Subgroups & Sampling Considerations.
  4. Interpretation.
  5. Run Test Rules.

MEASURE: Individuals Data

  1. Uses.
  2. Construction & Calculations.
  3. Assumptions & Sampling Considerations.
  4. Interpretation.
  5. Overview of Other Individuals Charts: Run Charts; Moving Average Charts; EWMA Charts.

MEASURE: Process Capability

  1. Histograms.
  2. Capability & Performance Indices (Interpretation; Estimating Error)

MEASURE: Attribute Charts

  1. Uses.
  2. Selection.
  3. Construction & Calculations.
  4. Sampling Considerations.

ANALYZE: Value Stream Analysis

  1. Definition of Waste.
  2. Analyzing Process for NVA using VSA.
  3. Analyzing Lead Time and Velocity

ANALYZE: Regression Analysis

  1. Cause & Effect Diagrams.
  2. Scatter Diagrams.
  3. Correlation, Stratification.
  4. Linear Model.
  5. Interpreting the ANOVA Table.
  6. Confidence & Prediction Limits.
  7. Residuals Analysis.
  8. Overview of Multiple Regression Tools
  9. DOE vs. Traditional Experiments & Data Mining

IMPROVE: Tools

  1. Improve Stage Objectives.
  2. Tools to Prioritize Improvement Opportunities.
  3. Defining New Process Flow.
  4. Lean Tools to reduce NVA and Achieve Flow, including 5S.
  5. Defining New Process Levels.
  6. Improving Lead Times and Setup Times.
  7. Tools to Define & Mitigate Failure Modes.

CONTROL: Tools

  1. Control Stage Objectives.
  2. Control Plans.
  3. Training.
  4. Measuring Improvement.