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Course Outline
Six Sigma and Organizational Goals
- Value of Six Sigma
- History and origins
- Cost of poor quality (COPQ)
- Organizational goals and Six Sigma projects
- Organizational drivers and metrics
- Design for Six Sigma (DFSS) methodologies
Define Phase: Tools and Methods
- Project identification and selection
- Process elements: Inputs and outputs
- Process owners and stakeholders
- Drafting the project charter
- Scope and problem statement
- Customer identification
- Voice of the Customer (VoC) and Critical to Quality (CTQ)
- Drafting SIPOC
- The case study
- Business results for projects
- Introduction to level calculations in Six Sigma
- Process and performance capability
- Process capability indices, 'Cp' and 'CpK'
- Project management basics
- Team dynamics and performance
- Introduction and tutorial sessions on Minitab
- Management and planning tools
Measure Phase: Introduction and Tools
- Process analysis and documentation
- Probability and statistics
- Statistical distributions
- Collecting and summarizing data
- Importance of the CE matrix
- Data normality
Analyze Phase: Introduction and Tools
- Statistical process control
- Control charts and stability issues
- Qualitative analysis and quick wins
- Process mapping
- Exploratory data analysis
- Hypothesis testing
- Design of Experiments (DOE)
- Root cause analysis
- Review of the seven quality tools
- Graphical analysis
- Histograms
- Analysis of Variance (ANOVA) and multi-plot diagrams
- Failure Mode and Effect Analysis (FMEA)
Improve and Control Phases: Introduction and Tools
- Piloting and implementation
- Pre and post capability
- Test of hypothesis
- Not golfing like Tiger? Six Sigma can help
- Class exercise: The catapult experiment
- Control phase
- Control plans
- Lean tools for process control
Introduction to Lean Enterprise
- Lean or Six Sigma?
- Lean principles in the organization
- Types of waste: Muda, Muri, and Mura
- Value Stream Mapping
- Spaghetti Diagram for distance analysis
- Other Lean tools (e.g., Pull system, POUS)
- Visual Management (5S)
- Mistake proofing
Requirements
- Knowledge of basic/intermediate statistics: It is suggested that participants take some time to review basic statistics. Books or e-learning modules could be used to refresh participants’ knowledge before attending the course.
- Familiarity with the seven basic problem-solving tools.
- Participants should have at least five years of practical experience in business processes.
35 Hours
