Lean 6 sigma

• What Is Lean Six Sigma?
• Where Did Lean Six Sigma Come From?
• Why Do Organizations Use Lean Six Sigma?
• Cost of Poor Quality
• Connect with the Customer
• Reduce Variation
• Focus on the Process
• Quantify the Dollar Impact
• Engage the People
• Lean Six Sigma Roles: White Belt, Yellow Belt, Green Belt, Black Belt, Master Black Belt, Champion/Sponsor.
• Project Type
• Project Selection
• DMAIC cycle overview: Define, Measure, Analyze, Improve, Control

• LEAN Principles
• Lean manufacturing introduction
• 10 Lean wastes, TIMWOOD+++ model
• Real example of Lean wastes
• Lean manufacturing concepts
• How does the LEAN and SIX SIGMA can combine together?
• Green belt roles and objectivesLean Wastes, Examples of Waste, LEAN Concepts

     –  Lean manufacturing and Lean in services

     –  Lean tools:

• Kaizen
• Jidoka
• PokaYoke
• SMED
• Visual Management
• Kanban
• Hejunka
• JIT
• Gemba
• Cellular manufacturing

     –  Lean tools (continue)

• A3 problem solving
• Standardized work
• Line balancing
• TPM, OEE, MTTR, MTBF

     –  Minitab software introduction for statistical analysis

     –  Visio software introduction

     –  Statistical analysis in Excel

     –  Create the Project Charter

• Business Case
• Problem Statement
• Goal Statement
• Scope

     –  Interpret the Voice of the Customer-VOC

     –  Kano Analysis

     –  Affinity Analysis

     –  Tree Diagram

     –  VOC-CTQ Matrix

• Understand the Current State
• Process Walk (Gemba Walk)
• Organizational Level Process Map
• SIPOC
• Value Stream Map – VSM
• Swimlane Map
• Spaghetti Map
• Develop Project Communication
• Communication Plan
• Case studies and practical exercises
• Project review

• A3 project
• Meeting Productivity
• The RACI Matrix
• Team Dynamics – The Alignment Model
• KPIVs & KPOVs
• Define phase wrap up

• Value Stream Definitions
• Measuring Customer Demand (Takt Time)
• Data Types
• Continuous and Discrete Measures
• Efficiency & Effectiveness
• Data Collection Plan
• Sampling calulation
• Case studies and practical exercies
• Project review

• Collect Baseline Data: DPU, DPO, DPMO, PPM, First time yield, Logistic yield, Throughput yield
• Detailed Process Map: As Is Mapping, To Be mapping, Swimming lane
• Fishbone Diagram
• X-Y Diagram
• Measurement Systems Analysis (MSA)
• Perform the step by step methodology in Variable and Attribute MSA’s
• Identify the various components of variation so corrections can be made and the gage error reduced
• The differences between Repeatability, Reproducibility, Accuracy and Precision

• Six Sigma Statistics
• Various statistics used to express location and spread of data
• The characteristics of a Normal Distribution
• Test for Normality
• The difference between Special Cause and Common Cause Variation
• A variety of graphs for data: Pareto, boxplot, dotplot, progress chart, Scatter, IMR, X-R, X-S, p, np, c, u, …
• Case studies and practical exercies
• Project review

• Capability for Continuous Data
• The impact of Non-normal data on the analysis presented in this module for continous capability
• Process performance analysis: cp, cpk, pp, ppk calculations

• Multi-Vari Analysis
• How data distributions become Non-normal when they are really Normal
• Basic tenets of the Central Limit Theorem
• Determine root causes
• Correlation analysis
• Case studies and practical exercies
• Project review

• Hypothesis Testing
• Failure Mode and Effect Analysis (FMEA)
• Regession analysis
• Non-Linear Regression Analysis
• Multiple Linear Regression Analysis (MLR)
• Residuals Analysis

• ANOVA-Analysis of Variable (ANOVA 1 way & 2 way)
• The reason for experimenting
• Design of experiment (DoE)-Full fractorial
• Case studies and practical exercies
• Project review

• Generating ideas for solutions
• Sequence number process
• Six thinking hats
• Brainstorming
• 635 method

• Selection and evaluation of solution
• Knock-out analysis
• Criterial-based matrix
• Cost-benefit analysis
• Case studies and practical exercies
• Project review

    –  Statistical Process Control – SPC

    –  Control charts

    –  Control Chart parameter calculations such as UCL, LCL and the Center Line

    –  Six sigma control plan (5 phases)

• Training
• Documentation
• Monitoring
• Response
• Align system and structure

     –  Control plan transition

• Lean Six Sigma final test (Multiple Choice Question)
• Group presentation: progress and result of Lean Six Sigma project
• Congratulation and cheer up