Course Outline
1.1 Section I – Organizational Roadblocks and Lean Management
- Organizational roadblocks
- Resistance Analysis
- Overview of all Continuous Improvement approaches
- Overview of Lean
- Overview of Six Sigma
- Lean Management explained — TAKT Time, Cycle Time, PCE, Lead Time, SWIP, Setup time, Changeover time
- Lean Tools explained — 5S, Kaizen, SMED, Heijunka
1.2 Section II – Pre-define DMAIC
- DMAIC versus DFSS
- Pre-define Pre-requisites and Qualifications
- Project Prioritization Matrix
- Introduction to Enterprise Wide view versus LOB view
- NPV and IRR
1.2.2 Define
- Champion’s transfer of project
- Team dynamics and facilitation
- Project Charter’s role
- SIPOC/COPIS map
- VOC/VOB/VOP
- CTQ, CTC, CTS
- VOC – CTQ Tree
- Kano Model
- Quality Function Deployment
- Baseline performance of Y
- Business Metrics for Y
- Rolled Throughput Yield (RTY)
- Statistical Definition of Six Sigma
1.3 Section III – Measure
- Objectives of Measure Phase
- Types of Data and Data Distribution models (Normal, Binomial and Poisson Distribution discussed)
- Scales of Data
- Measures of Central Tendency
- Measures of Dispersion
- Measurement Systems Analysis
- Variables GAGE RR
- Attribute RR
- Stability Check — Importance of Stability
- Capability Check — Cp, Cpk, Cpkm explained, How to understand Attribute Capability
- Variations, Variability and Capability
- Graphical tools to understand Data distribution
- Understanding Weibull (2 Parameter, 3 Parameter and Rayleigh) Distribution
- Correlating Calculations to Business Measures
- Checking Normality of Data (Anderson Darling, Ryan Joiner and Kolmogorov Smirnov)
1.4 Section IV – Analyze
- Objectives of Analyze
- Simple Linear Regression
- Multiple Linear Regression
- Curvilinear Regression
- Fishbone Diagram
- Pareto Charts
- Demarcating Common Causes and Special Causes
- Hypothesis Tests (Parametric and Non-Parametric tests)
- Statistical Validation
1.5 Section V – Improve
- Objectives of Improve
- Cost Benefit Analysis
- Solutions Prioritization Matrix
- Pugh Matrix
- Design of Experiments
- Introduction to DOE
- Basics of DOE
- Replication, Randomization and Blocking
- Main Effects and Interaction effects
- Full factorial experiments
- Fractional factorial experiments
- Screened Designs
- Response Surface Designs
- DOE with Regression
- DOE with example
1.6 Section VI – Control
- Taguchi’s Loss Function
- Control Charts (Variable Control Charts and Attribute Control Charts)
- Measurement System Re-analysis
- Control Plan and Project Storyboard Transfer
- Project Closure
- Introduction to Total Productive Maintenance
- Lean Process Improvement
Lean Process Improvement
- Understanding Lean
- The Toyota Production System
- The Toyota Production System House
- The Five Critical Improvement Concepts
- Understanding Value with the Kano Model
- Types of Waste
- Creating a Lean Enterprise
- Understanding Lean
- The Plan, Do, Study, Act (PDSA) Cycle
- Using the R-DMAIC-S Model
- Lean Thinking Tools
- Kaizen Events
- Data Gathering and Mapping
