This course will suit anyone who needs a thorough understanding of what Lean Six Sigma is and how it works in practice. The course includes a practical introduction and training on the full range of Lean Six Sigma tools. On completion of this course delegates will be able to work as leaders of Lean Six Sigma DMAIC projects. This course has proved to be equally relevant to manufacturing and service/transactional environments. The mix of delegates on the training is one of the attractions of attending this open programme. No prior knowledge or experience is required. Each participant receives a comprehensive delegate pack including Catalyst's Lean Six Sigma Improvement Toolbook, Statistical Tool guides, Worksheets, Project examples and support materials for use in Minitab.
This programme includes training on the advanced (statistical) tools required to execute the full range of Lean Six Sigma DMAIC projects. Practical exercises are incorporated to provide relevant scenarios for delegates. During these modules each delegate will be required to use statistical software. We use MINITAB™ Statistical Software in our training. No prior knowledge of Minitab is needed. A full practical introduction is included at the start of the programme. Delegates will need to bring a laptop computer.
Curriculum
The course begins with a 1 day Lean Six Sigma Awareness Workshop (optional).
Lean Six Sigma Foundation (4 days) introduces the Lean Six Sigma principles and methodology. Delegates then cover the Define, Measure, Analyse, Improve, Control [DMAIC] phases in depth including: change management; project definition; charters; stakeholder analysis; process mapping; voice of the customer; Critical-To-Quality (CTQ); input/output measures; data collection; control charts; root cause analysis and basic non-statistical tools. Lean techniques including Value Stream Maps, 5S, Flow are integrated into the programme to show how the two approaches can work together and complement each other. Several individual and team exercises are used to reinforce the concepts and encourage use of the tools.
Change Management (3 days) covers the “softer” change management tools required to lead successful Lean Six Sigma projects. Topics included in this 3-day module include change management, team building, and conflict resolution. This module is delivered through a combination of presentation, case studies, videos and hands-on exercises.
Stats Tools 1 (3 days) topics include an Introduction to MINITAB™ software followed by Normality (Central Limit Theorem, P-values, Transforming Data), Sampling (Random and Process Sampling, Determining Sample Sizes, Selecting Samples), Measurement System Analysis (Data Types, Gauge R&R, Attribute Agreement Analysis) and Introduction to Hypothesis Tests (Z- and t-tests).
Stats Tools 2 (3 days) topics include Hypothesis Tests (Analysis of Variance and Chi-Square Tests), Regression (Simple, Multiple, Binary Logistic), Control Charts (Continuous and Attribute Data Charts), Process Sigma (Short- and Long-Term Sigma, Determining Process Shift, Improvement Strategies) and an introduction to Designed Experiments (Full and Fractional Factorial Designs).
Black Belt Advanced Tools (3 days) covers more advanced statistical analysis tools. This module will begin with a challenging case study that will take the delegates from initial project charter development through a designed experiment. Subsequent advanced training in regression analysis (with indicator variables, curvilinear regression and logistic regression), hypothesis testing (non-parametric), control charts (non-Shewhart) and Design of Experiments (Taguchi) complete this module.
The Curriculum is built around a case study and a variety of practical exercises to give participants real hands on experience in application of DMADV techniques.
Design For Six Sigma Introduction and Overview (4 days)
The business challenges of Innovation, An overview of DMADV (the Design for Six Sigma Framework) and why it makes the critical difference, 7 principles of DMADV, Quality Function Deployment and the “House of Quality” , DMADV building on DMAIC, Linking DMADV with new product stage gate processes.
Define
Project start up, Market and customer segmentation, The change management challenges of DMADV.
Measure
Voice of the Customer & Introduction to advanced VOC techniques, House of Quality 1, Benchmarking and setting design goals, Design scorecards, Crystallising the value proposition.
Analyse
Functional Analysis, House of Quality 2, Creative Thinking, Concept selection.
Design
Building the design elements, Lean design tools, Simulation & Scale up (including design for operation), Capability Evaluation, Robust Designs & Tolerancing, Intro to DOE.
Verify
Piloting & testing, Control Planning, Handover to operations.
Preparing for a DFSS Implementation
How to prepare for a successful DFSS deployment. Why & how to integrate DFSS with existing stage gate New product development processes.
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