Objectives:

• Understand the Fundamentals of a Lean Six Sigma Quality System

• Understand principals and concepts of quality management

• Understand and apply the Basic Statistical Tools

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

• Roles & responsibilities

• DMAIC and DMADV Process Overview

• Available Lean Six Sigma green belt 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 6 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

• 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

• 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 / DMEDVI – 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

• 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

• 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.