Six Sigma Training

Overview of Six Sigma and the organization

• Six Sigma and organizational goals
  • Value of Six Sigma
  • Organizational goals and six sigma projects
  • Organizational drivers and metrics

• Lean Principles in the organization
  • Lean Concept
  • Value-streaming mapping

• Overview of DFSS ; DMAIC Vs DMADVC

Define Phase

• Project Identification
  • Project Selection
  • Process elements
  • Benchmarking
  • Process inputs and outputs
  • Owners and stakeholders

• Voice of the customer (VOC)
  • Customer Identification
  • Customer data
  • Customer requirements

• Project Management Basics
  • Project Charter
  • Project Scope
  • Project Metrics
  • Project Planning tools
  • Project documentation
  • Project risk analysis
  • Overview of Change Management
  • Project Closure

• Process Performance

• Team Stages and Dynamics

Measure Phase

• Statistical distributions

• Collecting and summarizing data
  • Type of data and measurement scales
  • Sampling and data collection methods
  • Descriptive statistics
  • Graphical methods

• Measurement systems analysis (MSA)

• Process and Performance Capability
  • Process performance vs. process specifications
  • Process capability studies
  • Process capability (Cp, Cpk) and Process performance (Pp, Ppk) indices
  • Short-term vs. long-term capability and sigma shift

Analysis Phase

• Exploratory data Analysis
  • Multi-vari studies
  • Correlation and liner regression

• Hypothesis testing
  • Basic & Tests for means, variances and proportions

Improve Phase

• Root cause analysis
• Lean Tools
  • Cycle-time reduction

Control Phase

• Statistical Process Control (SPC)
  • SPC Basics
  • Rational subgrouping
  • Control chart
• Control Plan

First Session : Six Sigma overview

• Introduction to Six Sigma
• Breakthrough strategies, Financial Benefits and Organizational Impact
• Difference between Six Sigma with other Quality Management and Improvement
• Philosophies
• Roles of six sigma players
• Deployment of six sigma
• Selection of six sigma projects
• Prioritization and projects

Second Session : Define phase

• Team and Project Charter, Roles Responsibilities
• SIPOC
• VOC
• Affinity Diagram
• Quality Function Deployment
• Critical to Quality (CTQ)
• Kano model
• Change Management

Third Session : Measure phase

• Process Mapping (As-Is Process)
• Understanding Data (Continuous Versus Discrete)
• Data Collection Techniques and Plan
• Understanding Basic Statistics (Central Tendency, Dispersion, Skewness)
• Measurement System Analysis (including continuous and Discrete Gage R&R)
• Understanding Variation and its causes
• Normal Distribution and Central Limit Theorem
• Control Charts (Run Chart, I – MR Chart, X bar – R Chart, X bar – s Chart, P Chart, NP
• Chart, C Chart, U chart)
• Measuring Process and Performance Capability
• Concept of “Waste” and VA/NVA ratio
• Pareto Diagram
• Histogram
• Box Plot
• Calculating Cycle time and Yield (FTY and RTY)
• Calculating Sigma Rating
• Baseline Performance
• Multi Vari Analysis

Fourth Session : Analyze phase

• Brainstorming
• Why – Why Analysis
• C&E diagram (Tree Diagram, Fishbone Diagram)
• Validation of Root Causes including GEMBA
• FMEA & Prioritization matrix
• Correlation and Regression
• Data visualization (VSM, Pareto Chart, Scatter plot)
• Value Added analysis (VA/NVA), Pull and Flow approach
• Benchmarking
• Hypothesis Testing,
• Z test
• t Test
• F Test
• Paired t Test
• Test for proportion
• Chi Square,
• ANOVA
• Non – Parametric Tests
• Introduction of DFSS
• DFSS & NPI
• Theory of Inventive Problem Solving (Triz)
• PUGH Matrix
• Fault Tree Analysis
• Analyze Phase Review

Fifth Session : Improve phase

• Techniques to identify Creative Solutions
• Brainstorming and Multi-voting
• Prioritize and Select Solutions
• Risk Assessment & FMEA
• Concept of Industrial Experimentation (DOE)
• Pilot and validate solution and implement change
• Full Scale Implementation
• Poka yoke
• Manage change

Sixth Session : Control phase

• Improvement Results
• Process Control methods (Control charts, Mistake-proofing, 5S. Visual Standards)
• Establishing Process Standards for Inputs, Process and Outputs
• Develop Process Management and Control Plan
• Standardization
• Training Plan
• Periodic Audit
• Review Implement process control
• Project Closure and Success Celebration

Enterprise-wide Planning and Deployment

• Strategic plan development
• Strategic plan alignment
• Deployment of six sigma systems
• Six sigma methodologies
• Opportunities for improvement
• Project identification
• Project qualification
• Stakeholder engagement
• Intervention techniques
• Creativity and innovation tools
• Risk analysis of projects and the pipeline
• Risk management
• Organizational design
• Systems thinking
• Organizational maturity and culture
• Organizational culture change techniques
• Organizational commitment
• Techniques to gain commitment
• Necessary organizational structure for deployment
• Communications with management
• Change management
• Organizational finance and business performance metrics
• Financial measures
• Business performance measures describe

Cross-functional Competencies

• Data gathering
• Internal organizational challenges
• Executive and team leadership roles

Project Management

• Project execution
• Cross-functional project assessment
• Project prioritization
• Project management principles
• Project financial tools
• Costing concepts

Training Design and Delivery

• Training needs analysis
• Training plans
• Training materials and curriculum development
• Adult learning theory
• Training delivery
• Training effectiveness evaluation

Mentoring Responsibilities

• Project reviews
• Project sizing Communications
• Mentoring black belts and green belts
• Technical reviews
• Team facilitation and meeting management
• Mentoring non-belt employees

Advanced Measurement Methods and Tools

• Process capability for non-normal data
• Measuring and modelling relationships between variables
• Multiple regression analysis
• Logistic regression analysis
• Model fitting for non-linear parameters
• Shainin DOE approaches