Lean Six Sigma Essentials
Instructor-led Online Class
Medium of Instruction: English
Trainer Trainee Ratio: 1:15 (MAX.)
Duration: 2 Days
COURSE OVERVIEW:
The Lean Six Sigma methodology provides the process improvement framework for an organization to increase the velocity of value creation in its processes with great customer satisfaction. It involves identifying improvement opportunities, analyzing root causes of inefficiencies, developing solutions and ensuring that the benefits are realized.
Lean Six Sigma Essentials, a 2-days training program helps participants to build good understanding of the key aspects of the Lean Six Sigma approaches, DMAIC (Define, Measure, Analyze, Improve and Control) methodology, and set of tools and techniques required to achieve process performance towards business goals.
This course is designed based on Lean Six Sigma Body of Knowledge of IASSC, ASQ and 6SigmaStudy. IASSC, ASQ and 6SigmaStudy are the independent third-party Lean Six Sigma Certification Bodies.
EXPECTED LEARNING OUTCOME:
- Demonstrate a good understanding of Lean Six Sigma approach and DMAIC methodology.
- Develop knowledge about some basic tools and techniques.
- Understand the different type of roles and responsibilities in Lean Six Sigma projects.
- Build good understanding to support improvements in their day-to-day work processes.
- Develop a mindset to think about different ways to solve the problem.
WHO SHOULD ATTEND?
- This course is suitable for front-line staff/supervisors who will support continuous improvement projects in their organization.
- The senior management or any professional can also attend this course to know how it can help to improve the way of doing things at workplace and even in life.
METHODOLOGY:
- Engaging and interactive way of course material delivery is carried out using the demonstration method and real life examples and exercises.
- Recap after a lunch/coffee/day break helps participants to enhance their understanding.
- Knowledge check exercise is conducted every day before the end of the class.
There is no official certification associated with this course. However, a "Certificate of Completion" will be issued to each participant who attends the course for at least 75% of the duration.
There are no prerequisites to take this course, although the participants will benefit if they are familiar with the nature of project work and organizational environment.
1.0 Introduction to Lean Six Sigma
1.1 Six Sigma Overview
1.1.1 Six Sigma Concept
1.1.2 Six Sigma Metrics
1.1.3 DMAIC (Define, Measure, Analyze, Improve and Control) Methodology
1.1.4 Design for Six Sigma
1.1.5 DMAIC Vs PDCA (Plan-Do-Check-act) and Business Process Re-engineering (BPR)
1.1.6 Roles and Responsibilities
1.2 Lean overview
1.2.1 Lean approach
1.2.2 Value-added and Non-value-added (waste)
1.2.3 Types of Waste
1.2.4 Lean Tools and Metrics
1.2.5 Kaizen Event and DMAIC
2.0 Define Phase
2.1 Identification of Improvement Opportunity
2.1.1 Voice Of the Customer (VOC) and Kano Model
2.1.2 Key Performance Indicators (KPIs)
2.1.3 Critical To Quality (CTQ)
2.1.4 VOC to CTQ Translation
2.1.5 CTQ Prioritization with Pareto Chart
2.2 Project Initiation and Planning
2.2.1 Stakeholder analysis and SIPOC
2.2.2 Project Selection and Project Metrics
2.2.3 Cost of Poor Quality (COPQ) and Financial Justification
2.2.4 Project charter and Key Elements
2.2.5 Project Planning—Work Breakdown Structure (WBS) and Gantt Chart
2.2.6 Team Development and Leadership
2.2.7 Communication Plan
3.0 Measure Phase
3.1 As-is Process Mapping
3.1.1 Value Stream Mapping (VSM)
3.1.2 Detailed Process Mapping
3.1.3 Process Inputs and Outputs identification
3.2 Process Data Collection
3.2.1 Data types
3.2.2 Population and Sample
3.2.3 Data Statistics Types
3.2.4 Data Collection Planning and Techniques
3.2.5 Sampling Methods and Bias
3.3 Data Accuracy and Precision
3.3.1 Accuracy—Bias, Linearity and Stability
3.3.2 Precision—Repeatability and Reproducibility
3.3.3 Measurement System Analysis Types
3.4 Process Capability and Stability
3.4.1 Process Capability—Baseline performance against target (customer/business requirement)
3.4.2 Process Stability—Baseline performance over time
4.0 Analyze Phase
4.1 Root Cause Analysis—Common Cause and Special Cause
4.1.1 Waste (non-value added activities) Analysis
4.1.2 Variation Patterns Analysis—Within, Between, and Over Time
4.2 Statistical Inference—Statistical Decision Making Process
4.2.1 Central Limit Theorem
4.2.2 Hypothesis Statements
4.2.3 Hypothesis Testing
4.3 Regression Analysis
4.3.1 Correlation
4.3.2 Regression Model
4.3.3 Residual Analysis
5.0 Improve Phase
5.1 Corrective Action and Preventive Action
5.2 Solution/Improvement Hierarchy
5.3 Potential Solutions
5.3.1 Industrial Revolution 4.0 (IR4.0)
5.3.2 TRIZ—Theory of Inventive Problem Solving
5.3.3 Lean Solutions—5 S, Visual Management, Standardized Work, Kanban and so on
5.3.4 Mistake-Proofing (Poka Yoke)
5.3.5 Regression Analysis
5.3.6 Design Of Experiment (DOE)
5.4 Selection of Best Solution and Risk Analysis
5.5 Pilot Implementation Plan
5.5.1 Pilot Run/Test
5.5.2 Solution Verification
6.0 Control Phase
6.1 Control Methods
6.1.1 Lean Control
6.1.2 Poka Yoka
6.1.3 Statistical Process Control (SPC)
6.2 Full Scale Implementation Plan
6.3 Control Plan
6.3.1 Control Plan Elements
6.3.2 Template
6.4 Project Closure
- Each participant will receive a copy of the course documentation and practice question set prepared by Emergence Skills.
- For Virtual Live Class (VLC), video recording will also be shared with all participants.
