Lean Six Sigma Fusion Training

Announcing Lean Six Sigma - Fusion Training
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Fusion Training Course Outline

Fusion is a new training system developed by PROMAX’s Lean Six Sigma Division that brings together Lean Six Sigma Black Belt, Green Belt and Champion/Sponsor training into one comprehensive, integrated course of study.  

Duration: 3-4 days consulting on project selection and four - one week training sessions (each three weeks apart)

 

 

Course Content:  first  Week

  • Lean Six Sigma, History of Quality, Strategy and Principles

  • Roles & responsibilities

  • DMAIC and DMADV Process Overview

  • Available Lean Six Sigma Training

  • Deployment Plan

  • Policy Deployment

  • Strategic Planning-Deploying Projects

  • System of Indicators– Key Performance Indicators, Balanced Scorecard, Flag System of Indicators

  • Define COPQ– Hidden Cost, Internal Failure Cost, Cost of Field Failures, Cost of Inspection, Cost of Prevention

  • Introduction to Lean Lean Six Sigma Tools- Value Stream Mapping , Types of Data, Data Collection, Measurement System Analysis, Process Capability, Descriptive Statistics, Hypothesis Testing, ANOVA, Design of Experiments, Lean Enterprise, SPC, FMEA, Weibull Analysis

  • Voice of the Customer – Customer CTQ’s, Sources of VOC, Dimensions of Quality the Kano Model, VOC Process Planning

  • Project Selection  

  • Management Reviews – Definition and Purpose, How to Conduct a review and Guidelines for Management

Formal Champion Training is completed on the third day -- Ends Here

  • Define– Indicators, Problem Definition, Project Charter, Project Planning Worksheet

  • Process Management – Definition of Core, Macro Micro/Enabling, Select Top Priority Process, Process Flowcharting – construct flowchart of identified process, selecting Process Indicators

  • Measure – Purpose of Data, Types of Data

  •  Basic Sampling - Simple Random Sampling, Systematic Sampling

  •  Data Collection – Principles of Data Collection, Sources of Data, How to design a Checksheet

  • Displaying Data – Histograms, Frequency Charts, Line Graphs, Run Charts, Bar Charts, Radar Charts

  • Project Planning – Status, Action Planning

Course Content:  second   Week

  • Analyze – Logic of Root Cause Analysis

  • Basic Probability & Statistics – Descriptive vs. Inferential Statistics, Measures of Central Tendency, Measures of Dispersion, Basic Probability

  • Stratification – Pareto Charts

  • Cause/Effect Analysis – Potential Root Causes, Cause & Effect Diagram, Root Cause Verification

  • Improve and Implement – Identifying Countermeasures, Cost/Benefit Analysis, Force Field Analysis, Develop Implementation Plan, Confirm Results

  • DFSS / DMADV – Define-Measure-Evaluate Design Concepts-Develop Final Design – Validate Design – Implement Design

  • Control – Control of Processes/Products –Standardize – Standard Operating Procedures, Eliminate Variation , Control Charts

  • Introduction to Statistical Process Control – Understanding Variation, Types of Variation, Sources of Variation, Control Chart Definitions, Control Chart Components, How to use Control Charts, Interpreting Control Charts

  • Variables Control Charts – X bar R Chart, X, mR Chart

  • Attribute Control Charts – np Chart, p Chart, c Chart, u Chart, How to select the proper control chart  

  • Lean Enterprise – Principles for a Lean Enterprise

  • Components of Lean – Operations Layout and Balancing, Design for Production, Mistake Proofing, Batch Size Reduction, Customer Demand Pull The Value Stream Map

  • Waste Elimination

  • 8 Sources of Waste

  • Continuous One-Piece Workflow

  • Demand Pull Processing

  • Kan Ban

  • 5 S’s  - Sort, Store, Shine, Standardize, Sustain

  • Mistake Proofing

  • Plan to Mitigate Top Priority Risks – Identify actions to attack risks – develop action plan, estimate post seriousness after mitigation, estimate Post-Probability of Occurrence – Calculate Post-Risk Prioritization Number.

  Formal Green Belt Training is completed at the end of the 2nd Week - Ends here


Course Content:  Third   Week

  • Advanced Probability and Statistics – Review of Descriptive Statistics

  • Introduction to Minitab – Worksheet and Project File Structure, Session Window, Using Minitab Worksheets, Manipulating Data with Minitab

  • Characteristics of the Normal Curve – Chebyshev’s Theorem, Calculating Percentiles.

  • Standard Normal Transformation

  • Probability Definitions- Permutations and Combinations, Laws of Probability

  • Advanced Sampling –Sampling Rules of Thumb, Sampling Definitions, Sample Size Formulas, Sampling Error, Significance Level.

  • Other Sampling Techniques-Two-Stage Sampling, Stratified Sampling, Cluster Sampling, Confidence Intervals.

  • Measurement Systems Analysis-Measurement System Components, Sources of Observed Variation, How to Conduct MSA Studies, Attribute MSA, Variables MSA.

  • Process Capability- Control Limits vs. Customer Specifications, Loss Function Concept, Process Capability Indices, Shifts and Drifts (1.5 Sigma Shift).

  • Calculating Process Yield

  • Comparing Stability and Capability

  • Hypothesis Testing- Detecting Differences, The Null Hypothesis, The Alternate Hypothesis, Visualizing Risks, Hypothesis Testing Procedure, Hypothesis Testing Decision Tree, Test of Means-Variance Known, Test of Means- Variance Unknown, Test of Variances vs. Standard, Test of Two Population Variances, Test of Proportions vs. Standard, Test of Two Population Proportions

  • Non Parametric Tests of Hypothesis -Test for Normality, Tests of Medians, Test of Two Population Medians, Test of Multiple Medians

  • Correlation/Regression Analysis

  • ANOVA – Test of Multiple Means, Analysis of Means

  • Introduction to Design of Experiments – One factor at a time experiments, DOE Process, DOE Planning, DOE Applications

  • DOE Activity Instructions

  • Build DOE Model – Test and Modify DOE Model, DOE Catapult Competition


Course Content:  Fourth   Week

 

  • Benchmarking -   Reasons for Benchmarking , Types of Benchmarking, Basic Benchmarking Methodology, Preparing for Benchmarking, Benchmarking Ethics

  • Reliability – Basic Reliability Methods,  Reliability Management

  • Fault Tree Analysis – Causes of Undesirable Events, Fault Tree Terms and Symbols, Fault Tree Diagram, Quantifying the Fault Tree

  • Quantifying Reliability - Measures of Reliability, Data Components, Goals of Reliability Data Analysis, Censored Data, Life Data Models, Calculating Mean Time Between Failures

  • Weibull Analysis – Calculating Failure Rate, The Bathtub Curve, Weibull Distribution, Failure Data Analysis

  • Failure Modes and Effects Analysis (FMEA) – Identify Failure Modes and Effects, Assess Seriousness, Identify Potential Causes, Estimate probability, Identify Detect ability, Measure Controls – Calculate Risk Prioritization Number  

  • Management and Planning Tools –7 New Management & Planning Tools – Relationship Diagram, Affinity Diagram, Systematic Diagram, Matrix Diagram, Matrix Data Analysis, Arrow Diagram, Process Decision Program Chart

Green Belt and Black Belt Recap

  • Project Presentations - Champions Review

  • Celebration

 

Course Materials:

  • Course Manuals (Disk)

  • PROMAX Six Sigma Pocket Guide

  • PROMAX Lean Enterprise Pocket Guide

  • Minitab 14 Demo Software for Black Belts Only

  • Computer is only required for Black Belt participants (not provided by PROMAX)

 


Contact PROMAX at 321-725-430

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PROMAX Consulting Services, Inc.  
Telephone 321-258-6316  
General Information:  mail@promaxconsulting.com

Copyright 2011 by PROMAX Consulting Services, Inc.