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• Updating ....

• Power Point presentation, group presentation
• Join the discussion, guide and coaching through the practice of connecting to the actual work (games, exercises)
• Watch the video clip, role playing
• Handle real situations and with reference books
• Tell the story/Sharing real experiences
• Each participants will be practicing and receiveing suggestions, editing in class

• SIX SIGMA AND LEAN OVERVIEW

  1. Six sigma and Lean concepts
     • The concepts of six sigma
       • -   Motorola story
       • -   Normal Distribution and Six Sigma
       • -   Process capacity index & Process performance index
       • -   Determing the process sigma level
       • -   Process sigma levels - common system for measurement
       • -   Process sigma level calculation
       • -   Rigorous and structured improvement methodology – DMAIC
       • -   Desgin for Six sigma - DMADV
     • What are the concepts of Lean?
       • -   Toyota story
       • -   Be customer focused: Be on-time, responsive, flexible, and fast
       • -   Value-Added vs. Non-Value-Added Activities
       • -   The 8 forms of waste
       • -   The seven principles of Lean manufacturing
     • History of Six Six sigma and Lean Concepts
     • Lean Six Sigma Objectivies
     • How do you resolve ANY Issue with a Product, Process, or Service

     Intergrating Lean Concepts within the DMAIC Improvement Process

  2. Lean Six Sigma Project Simulation
     • Lean Six Sigma Experience
     • Sailboat Company LSS Simulation
     • LSS Project Simulation - DMAIC Improvement Process
     • LSS Project Simulation - Define Phase
     • LSS Project Simulation - Measure Phase
     • LSS Project Simulation - Analyze Phase
     • LSS Project Simulation - Improve Phase
     • LSS Project Simulation - Control Phase
     • LSS Project Simulation - Business Impact
     • Quiz - Sailboat Company LSS Simulation

• DEFINE PHASE OF DMAIC

  1. Define the Project
     • Define Phase Overview
     • Project Charter
     • Communication Plan
     • Quality Cost and Business Case
     • SIPOC Process Mapping
  2. Understand Your Customers
     • Voice of the Customer - Data Collection
     • Voice of the Customer - Affinity Diagram
     • Voice of the Customer - Kano Model
     • Voice of the Customer - CTQ Tree
     • Movie - CTQ Tree
  3. Mapping the Current State
     • Process Mapping Basics
     • Value Stream Mapping
     • Deployment Process Mapping
     • Process Activity Analysis
  4. Teamwork
     • Teamwork in Meetings
     • Project Planning
  5. Review and Exam
     • Define Phase Review
     • Exam - Define Phase

• MEASURE PHASE OF DMAIC

  1. Math and Data Collection
     • Introduction to Math
     • Introduction to Minitab
     • Exercise Minitab First Look (parts 1,2,3,4)
     • Bottle Case Study
     • Data Collection
     • Exercise Data Collection Plan
     • Exercise MnM Data Collection
     • Exercise Operational Definition and 2 Factor Attribute Check Sheet
     • Minitab Exercise Data Entry and Pareto Analysis
     • Exam Math and Data Collection
  2. Basic Stats and Measurement System Analysis
     • Basic Statistics
     • Minitab Exercise Central Tendency
     • Minitab Exercise Dispersion
     • Minitab Exercise Impact of Mean and Standard Deviation Changes
     • Measurement System Analysis (MSA)
     • Minitab Exercise MSA for Attributes Data
     • Minitab Exercise MSA for Continuous Data
     • Minitab Exercise MSA for Measuring Rubber Bands
     • Exam Basic Statistics and MSA
  3. Descriptive Stats and Sampling
     • Descriptive Statistics
     • Nature of Variation
     • Descriptive Statistics
     • Minitab Exercise Descriptive Statistics
     • Histograms
     • Minitab Exercise Histograms
     • Individual Measurements Control Charts
     • Minitab Exercise I-MR Charts
     • Sampling Plans
     • Exercise Discrete Data Sampling
     • Exercise Continuous Data Sampling
     • Exam Descriptive Statistics and Sampling
  4. Setting the Baseline
     • Machining Case Study
     • Pareto Analysis
     • Minitab Exercise Pareto Analysis
     • Baselining and Process Sigma
     • Baseline and Process Sigma
     • Exercise Process Sigma Continuous Data
     • Exercise Process Sigma Discrete Data
  5. Review and Exam
     • Measure Phase Review
     • Final Exam Measure Phase

• ANALYZE PHASE OF DMAIC

  1. Lean Root Cause Analysis
     • Lean RCA Intro
     • Value Stream mapping
     • Process Analysis
       • -   Pull System Illustrated
       • -   Process Activity Analysis
       • -   Kanban Calculation
       • -   Kanbans in Action
     • Cause and Effect
     • FMEA, FMEA Template
     • Organizing the Data
     • Analysis Type and Use
     • Root Cause Analysis Exam
  2. Hypothesis Testing
     • Minitab Review
     • Hypothesis Testing Introduction
       • -   P Value Explained 1
     • Test for Normality
       • -   Normality Test in Minitab
     • T Test
       • -   T Test in Minitab
       • -   Making a Helicopter
       • -   T Test Movie and Exercise
     • Paired T Test
       • -   Paired T Test in Minitab
       • -   Paired T Test Movie and Exercise
     • ANOVA – Analysis of Variance
       • -   ANOVA in Minitab
       • -   ANOVA Movie and Exercise
       • -   F Statistics and p Value
     • Equal Variances
       • -   Test for Equal Variances in Minitab
       • -   Test for Equal Variances Exercise
     • Hypothesis Testing Exam
  3. TeamWork
     • Teamwork Listen & Think
  4. Regression
     • Correlation and Scatterplots
       • -   Scatterplot in Minitab
     • Linear Regression
       • -   Regression in Minitab
       • -   Helicopter Regression in Minitab
       • -   Regression Movie and Exercise
     • Regression Interpretation
     • Regression Exam
  5. Designed Experiments
     • Intro to DOE
     • 2 Factor DOE
       • -   2 Factor DOE in Minitab
       • -   2 Factor DOE Movie
       • -   Exercise Conduct 2 Factor DOE
     • 3 Factor DOE
       • -   3 Factor DOE in Minitab
       • -   3 Factor DOE Movie
       • -   Exercise Conduct 3 Factor DOE
     • DOE Exam
  6. Analyze Review
     • Problem Cause Solution Matrix
     • Analyze Review
     • Final Exam

• IMPROVE PHASE OF DMAIC

  1. Developing Solutions
     • Developing Creative Solutions
     • Brute Think
     • Evaluating and Selecting Solutions
     • Simple and Pugh Prioritization Matrices
     • QFD Matrix Example
     • Cost Benefit Analysis
     • Dupont Analysis Example
     • Cost per PPM
     • Layout and process flow
     • Kanban
     • Process Sigma Savings Calculator
     • TPM - Total productive maintenance
     • Developing Solutions Exam
  2. Piloting Solutions
     • Risks, Rewards, and Piloting
     • Minitab Piloting Improvements
     • FMEA Evaluating Risks Example
  3. Gemba Kaizen
     • Gemba Kaizen Introduction
     • Seven Wastes
     • Housekeeping 5S
     • Standardization
     • Poka Yoke Methods
     • Kaizen Improvement Process
     • Gemba Kaizen Exam
  4. Implementation Planning
     • Planning the Implementation
  5. Teamwork
     • Teamwork - Influencing Skills
  6. Improve Phase Review
     • Improve Review
     • Improve Phase Final Exam

• CONTROL PHASE OF DMAIC

  1. Quality Control
     • Quality Control
     • Active Follow Up Exercise
     • Control Plan Exercise
     • Standardization & Documentation
     • Standards Exercise in Minitab
     • Quality Control Exam
  2. Maintaining the Gains
     • Monitoring and Evaluating the Results
     • Process Control Charts in Minitab for Attributes
     • Process Control Charts in Minitab for Variables
     • Evaluating Before and After DMAIC in Minitab
     • Evaluating Process Sigma Level
     • Visual Management System
     • Process Ownership and Lessons Learned
     • Process standardized
     • 5S
     • TPM
     • Kanban
     • Maintaining the Gains Exam
  3. Control Phase Review
     • Control Phase Review
     • DMAIC Deliverables Review
     • Completing Your Project for Certification
     • Control Final Exam