Six Sigma

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Learning Objectives

The objective of this course is to develop a comprehensive set of skills that will let you to function effectively as a Lean Six Sigma Green Belt.

You will learn the Lean Six Sigma Green Belt body of knowledge, practice techniques for both quantitative and non quantitative analysis, and gain the team leadership skills necessary to get projects across the goal line.

Pre-requisites

• Operates in support of or under the supervision of a Six Sigma Black Belt
• Analyzes and solves quality problems
• Involved in quality improvement projects
• Participated in a project, but has not led a project
• Has at least three years of work experience
• Has ability to demonstrate their knowledge of Six Sigma tools and processes

Session 1: Introduction to Lean Six Sigma

•Introduction
• Higher Standards for Higher Performance
• Input Determines Output
• Lean Six Sigma Defined
• What's In a Name?
• The 5 Lean Principles
• The 8 Forms of Waste
• Success Stories
• The Sigma Level
• The 99.9% Problem
• DNA of a Champion
•Lean Six Sigma Framework
• DMAIC - The Lean Six Sigma Improvement Process
• Lean and DMAIC
• Thought Process Mapping - Toolset
• Organizing for Success
• Working Relationships
• Introduction to EngineRoom®
• Exercises and Quiz

Session 2: Define I - Starting a Project and Leading Teams

• Getting Started - Project Initiation
• Project Selection Toolset
• Project Charter Toolset
• Project Planning & Tracking Toolset
•Leadership Thinking
• Robot Leadership
• Fueling The Improvement Engine
• Leading Teams
• Developing an Effective Team
• Improving Team Development
• 4 Conversations Toolset
• Leading Change
• Leading Change - Continued
• Success Factors For Effective Change Management
• Stakeholder Analysis - RACI Matrix
• Leadership Reflection
• Exercises and Quiz

Session 3: Define II - Voice of the Customer

• Voice Of The Customer
• Focus on The Customer
•Understanding Customer Requirements
• Where to Go For Customer Requirements
• Conducting Surveys
• Survey Considerations
• 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
• Exercises and Quiz

Session 4: Define III - Mapping the Process

• Drawing a Process Picture
• Process Thinking
• The Source of Value
• Value Stream Leverage
• Process Mapping - Overview
• Process Mapping (SIPOC) Toolset
• Flow Charts
• Value-Added Flow Charts
• Spaghetti Charts
• Takt Time
• Value Stream Mapping Toolset
• Define Tollgate - Progress Review
• Exercises and Quiz

Session 5: Measure I - Measurements and Basic Statistics

• Measurements and Basic Statistics
• Business Problem Solving
• Basic Statistical Terms
• Descriptive and Inferential Statistics
• Measurements
• Discrete vs. Continuous Measurements
• Measurement Subjects
• Graphical Summaries
• Pareto Chart Toolset
• Histogram Toolset
• Understanding Variation
• Measuring Central Tendency
• Quantifying Process Variability
• The Normal Distribution
• Exercises and Quiz

Session 6: Measure II - Measurement System Analysis

• Measurement System Analysis - Introduction
• Measurement As A Process
• Cause & Effect Matrix Toolset
• The Analysis of Measurement Systems
• The Requirements of Measurement Systems
• Variable MSA - Gauge 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
• Calculating the Sigma Level - Toolset
• Exercises and Quiz

Session 7: Measure III - Charting Process Behavior

• Introduction - Charting Process Behavior
• Trend Chart Toolset
• 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 - Toolsetv • Attribute Control Chart Toolset
• X-bar and R Chart Toolset
• Process Capability Toolset
• Measure Tollgate - Progress Review
• Exercises and Quiz

Session 8: Analyze I - Identifying Potential Root Causes

•ANALYZE I - Introduction
• Finding The Root Cause
• Cause & Effect Diagram Toolset
• 5-Why, 1-Howv
• A Combination of 5-Why, Pareto, and Trend Chartsv
• Scatter Plot Toolset
• Correlation and Regression Analysis
• Multiple Regression Toolset
• Factors In Determining Sample Size
• Estimating Population Mean
• Exercises and Quiz

Session 9: Analyze II - Hypothesis Testing

•ANALYZE II - Introduction
• 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 Toolset
• Comparing Two Means - t-Test Toolset
• Comparing Multiple Means - ANOVA Toolset
• Confidence Intervals - Least Significant Difference
• Hypothesis Testing Learning Lab
• Analyze Tollgate - Progress Review
• Exercises and Quiz

Session 10: Improve

•Improve
• Design for Lean Six Sigma (DFSS)
• Benchmarking
• Brainstorming
• Narrowing Down The List of Ideas
• FMEA Toolset
•Error-proofing
• Prioritizing and Selecting a Solution
• The A3 One-Page Report
• Continuous Flow Toolset
• Balancing Capacity with Demand
• Quick Changeover Toolset
• Cellular Processing Toolset
• Pull System Overview
• Pull Scheduling
• Pull Systems
• Kaizen Toolset
• Corrective Action Matrix
• Piloting a Solution
•System Dynamics Toolset
•Improve Tollgate - Progress Review
• Exercises and Quiz

Session 11: Control

• Control
• Control Charts Revisited
• The Process Control Plan
• More On FMEA
• Visual Control
•5-S Approach
• Total Productive Maintenance
• TPM Objectives & Benefits
•TPM Metrics
• Best Practices and Lessons Learned
• Standardized Work - Documenting Process Changes
• Ending the Project
• Control Tollgate - Progress Review
• Exercises and Quiz
• Course Completion
• The Lean Six Sigma Journey

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