Curs Lean Six Sigma – Black Belt

Module 1 – Introduction Lean Six Sigma – DMAIC Methodology

• What is Six Sigma
• DMAIC – A logical Approach to Problem Solving
• What is Lean?
• Lean and the Six Sigma
• Six Sigma (DMAIC) Structure
  • Six Sigma Project Phases
  • Six Sigma Project Deliverables
  • Six Sigma Project Team
  • Six Sigma TemplatesBuilding a Lean Six Sigma Program
• Different Types of Lean Six Sigma Projects
• Where do Lean Six Sigma Projects come from?
• Managing Lean Six Sigma Projects
• Minitab – Overview

Module 2 – Six Sigma  – DEFINE Phase

• Problem Statement
• Goal Statement
• Cost of Poor Quality (COPQ)
• Voice of the Customer (VOC), Kano Analysis
• House of Quality
• Critical to Quality (CTQ) Trees
• SIPOC – High Level Process Mapping
• Project Structure and Project Plans
• Stakeholder Analysis
• Project Documents
• Facilitation Skills
• Effective Teams and Meetings
• Project Charter
• DEFINE Phase Review

DEFINE – Practical Six Sigma Process Improvement Simulation/Workshops

• Workshop D 1:
  • Develop a threat / opportunity matrix
  • Develop a SIPOC
  • Develop stakeholder analysis and influence strategy
• Workshop D 2:
  • Perform a KANO analysis
  • Define CTQ: output characteristic, KPI, measurement criteria, target, specification , defect/operational definitions
• Workshop D 3:
  • Develop a High Level AS-IS process map (cross-functional flowchart
• Workshop D 4:
  • Develop the Project Charter

Module 3.  Six Sigma – MEASURE Phase

• Key Performance Indicators (KPIs)
• KPI Trees
• Lean Measures (PCE,OEE, Takt Time, etc)
• Statistics for process “Position” / “Spread”
• Operational Definitions
• Data Worlds (Continuous/Count/Atribute Data)
• Data Collection Methods
• Data Collection Plans and Sampling
• Minimum Sample Sizes
• Sampling Frequency
• Contextual Data
• Measurement System Analysis (MSA)
  • Bias and Precision
  • Measurement System Resolution
  • Gauge Repeatability & Reproducibility (GR&R)
  • Continuous GR&R in Minitab
  • Attribute GR&R in Minitab
  • MSA Drilldown
• Distribution shapes and the Normal Distributions
• Normal Distribution in Theory and Practice
• 1st pass Analysis
• Process Stability and Short/Long Term Variation
• Process Capability
  • Capability Analysis Normal Data
  • Capability Analysis Non-normal Data
  • Cp, Cpk, PPM, DPMO measures
  • Calculating % Defective
  • Sigma Levels
  • Sigma Shift
• Measure Phase Review

MEASURE – Practical Six Sigma Process Improvement Simulation/Workshops

• Workshop M 1: Develop data collection plan in order to take relevant measures about the process during Process Simulation
  • Select segmentation factors
  • Define operational definitions for process accuracy/error level and total cycle time
  • Define with your team a data collection process
  • Create a data collection form to record data for your AS-IS process
  • Calculate required sample size for measuring the process
• Workshop M 2: Simulate and Measure your Process
  • run process for 40 customers and measure your process
• Workshop M 3: Establish Process Baseline by calculating:
  • Accuracy: DPMO-method
  • Cycle time: z-value
  • Convert to Sigma Levels

Module 4.  ANALYZE Phase

• Process Analysis (Process Door Approach)
  • Process Mapping
  • Value Stream Mapping
  • Time Value Maps
  • The Five Laws of Lean
  • The Seven Wastes
  • Spaghetti Diagrams
  • Brainstorming
  • 5 Whys
  • Fishbone (Cause and Effect) Diagrams
  • Affinity Diagrams
  • Failure Mode and Effect Analysis (FMEA)
• Process Data Analysis (Data Door Approach)
  • Minitab – Data Types, Manipulation and Graphs
  • Minitab’s “Display Descriptive Statistics”
  • Histograms
  • Dot Plots
  • Minitab’s Graphical Summary
  • Probability Plots
  • Time Series Plots
  • Run Charts
  • Pareto Analysis/Charts
  • Data Stratification
  • Box Plots
  • Individual Value Plots
  • 100% Stacked Bar Charts
  • Scatter Plots
  • Matrix Plots
  • Graphical Results to Statistical Significance
  • Confidence Intervals
• Hypothesis testing
• Hypothesis Tests for Average
  • 2 Sample t-test
  • 1 Sample t-test
  • Paired t-test
  • One Way ANOVA
  • Tuckey’s Quick Test
• Hypothesis Tests for Median
  • 1 Sample Sign Test
  • Kruskal-Wallis Test
  • Mood’s Median Test
• Hypothesis Tests for Variation
  • Minitab’s Test for Equal Variance
• Hypothesis Tests for Proportions
  • 1 Proportion test
  • 2 Proportion test
  • Chi Square test
• Normality Test (Anderson Darling)
• Individual Distribution Identification
• Correlation and Regression Overview
  • Pearson Coefficient
  • Simple Regression and Mintab’s Fitted Line Plot
  • Checking the model (residuals analysis)
  • Multiple Regression
  • Binary Logistic Regression
• Design of Experiments (DOE) – Overview
  • DOE – Approach
  • 2-Level Full Factorial Designs
  • Full Factorial Example
  • Analyzing the results
  • Refining the model
  • Calculating the process model
  • Fractional Factorial Designs
  • Fractional Factorial Example
  • Analyzing the results
  • Checking the confounding
  • Minitab’s Design of Experiments
• ANALYZE Phase Review

ANALYZE – Practical Six Sigma Process Improvement Simulation/Workshops

• Workshop A 1: Identify and validate root causes and show Vital Few.
  • Analyze the process (Data segmentation and stratification , Fishbone and 5 Why’s, Regression)
  • Prepare a graphical display of the process information.
  • Show the Vital Few

Module 5. Six Sigma – IMPROVE Phase

• Negative Brainstorming and Assumptions Busting
• Error Proofing and Benchmarking
• Chain Letters and Billboards
• SCAMPER
• Assessment Criteria
• Paired Comparisons
• Prioritization Matrix
• Pugh Matrix
• Solution Screening and Pilot Studies
• 5S
• Visual Management
• IMPROVE phase Review

IMPROVE – Practical Six Sigma Process Improvement Simulation/Workshops

• Workshop I 1: Generate and select a solution with your team
  • Draw a TO-BE process map of the new process (solution)
  • Develop a FMEA for the new process
  • Solution cost / benefit analysis
  • Prepare a presentation for your Milestone review
• Workshop I 2: Implement your new process, measure the data and calculate improved sigma level.
  • Make an implementation plan for the new process (Room set-up, teams, training, etc)
  • Adapt all necessary forms according to your new process
  • Develop a simplified data collection plan (operational definition, sample size)
  • Present solution
• Workshop I 3:Run process again and measure data
  • Measure new process
  • Draw control chart
  • calculate new sigma value (new process capability)
  • Prepare Milestone Review

Module 6. CONTROL Phase

• Control Phase – Roadmap & Overview
• Statistical Process Control (SPC) – Process Charts for Managing the process
  • Overview SPC – Approach
  • I-MR Charts
  • X Bar – R Charts
  • U Charts
  • P Charts
• Control Plans
• Standardized Processes
• Project Documentation
  • Process Procedures
  • Solution Transfer Plan
• Process Monitoring Plan
  • Creating Process KPI and Dashboards
  • Response Plan Solution Roll-out
• Project Closure
• • Project Reports and Action Logs
  • Lessons Learned
• CONTROL Phase – Review

Module 7 – Six Sigma (DMAIC) Methodology Review

La sfarsitul acestui training participantii vor avea cunostintele necesare si vor fi capabili:

• Sa aplice metododolgia Lean Six Sigma  in proiecte complexe privind  imbunatatirea proceselor utilizand ciclul DMAIC
• Sa foloseasca metode statistice avansate pentru analiza proceselor
• Sa foloseasca un set de instrumente si metode de masurare a proceselor existente si sa stabileasca care este performanta actuala de la care se porneste efortul de imbunatatire (as is)
• sa identifice cauzele problemelor folosind un set de tehnici si concepte specifice
• sa identifice solutii de imbunatatire (inc KPIs) si sa monitorizeze atinderea perfomantei dorite (to be)
• Sa stabileasca structuri si metode de control ale proceselor de business

• Persoanele care au o deja formare in Six Sigma, au participat in proiecte Six Sigma si doresc sa aprofundeze aparatul matematic statistic
• Persoane certificate Six Sigma Green Belt
• Persoanele care doresc sa se pregateasca pentru examenul de certificare Six Sigma Black Belt

Pentru a beneficia din plin de acest training recomandam participantilor:

• sa aiba o experienta practica in aplicarea metodologiei Six Sigma si cel putin un proiect derulat cu succes
• sau echivalent, sa detina certificarea Green Belt