Curs Lean Six Sigma – Fundamentals

1 – Introduction in Lean Six Sigma (DMAIC) Methodology

• What is Six Sigma
• Cost Of Poor Quality. Why do we need process improvement?
• Applying Six Sigma in real life – examples of projects
• Six Sigma Organization. Roles in Six Sigma projects:Team, Green Belt, White Belt, Black Belt, Champions, Six Sigma Steering Comitee

• Lean Six Sigma Methodology overview (DMAIC)

  • Six Sigma Project Phases
  • Six Sigma Project Deliverables
  • Six Sigma Project Team
  • Six Sigma Templates
• Lean principles
• Case Studies, Examples of real Six Sigma projects

2 – Lean Six Sigma – DEFINE Phase

• Define Project Roadmap & Objectives
• Defining the Customer’ Requirements
• Identifying and segmenting key Customers.
  • Stakeholder Analysis
  • Stakeholder Map
• Voice Of The Customer (VOC)
• Critical to Quality Requirements (CTQs)
  • Translating Voice of the Customer (VOC) in CTQs
  • Developing CTQs – Process Output Characteristics, KPIs
• Analyzing & Prioritizing Customer Requirements
  • Kano Analysis

• Project Charter – Planning and Organizing the Six Sigma Project

  • Six Sigma Project Charter Example
• Defining the Project
  • Process Stakeholder Analysis
  • Organization Chart
  • High-Level Process Mapping
  • Process Levels
  • SIPOC
• Setting the Objectives for Process Improvement

DEFINE – Practical Lean Six Sigma Process Improvement Simulation

• Develop a threat / opportunity matrix
• Develop a SIPOC
• Develop stakeholder analysis and influence strategy
• Perform a KANO analysis
• Define CTQ: output characteristic, KPI, measurement criteria, target, specification , defect/operational definitions
• Develop an AS-IS process map (cross-functional flowchart)

3 – Lean Six Sigma MEASURE Phase

• Lean Six Sigma Measure Phase – Introduction & Objectives
• Basic Measurement Principles
• Identifying Process Input / Output Measure
  • X/Y Matrix
• Data Collection
  • Segmentation
  • Operational Definition Elements
  • Sampling
  • Principles of Measurement systems analysis – MSA
  • Data Collection Plan
• Understanding the Data obtained from process measurement
  • Data Analysis. Types of Data
  • Histograms
  • Pareto Chart
  • Pie Chart
  • The Normal Curve
  • Normal Probability Plot
  • Central Tendency
  • Run Charts
  • Control Charts
• Process Capability Measurement and Analysis
  • Process Baseline – current process performance
  • Baseline Process Performance
    • Sigma Level
    • DPMO
  • Determining Process Sigma Level
  • Defects per milion opportunities (DPMO)
  • Sigmal Level for continous and discrete data
  • Proportion Defective & Process Yield Calculation
  • Process Capability due to Short and Long Term Variation

MEASURE – Practical Six Sigma Process Improvement Simulation

• Develop data collection plan
• 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
• Simulate and Measure your Process
• Establish Process Baseline
• Use Minitab to measure process capability.

4 – Lean Six Sigma ANALYZE Phase

• Lean Six Sigma Analyze phase – Introduction
• Overview of process Analysis Tools
• Process Analysis
  • Process Map Analysis. Sub-process mapping.
  • Flowcharts
  • Workflow analysis
  • Process Value Analysis
  • Cause & Effect Diagram
  • The Five Whys
• Graphical Data Analysis. Graphical Analysis Tools
  • Segmentation and Stratification
  • Pareto Chart
  • Scatter Diagram. Veryfing process causes for variation
• Statistical Process Analysis
  • Linear Regression
• Identifying the Root Causes for process problems

Lean Six Sigma ANALYZE – Practical Six Sigma Process Improvement Simulation

• 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

 5 – Lean Six Sigma IMPROVE Phase

• Lean Six Sigma Improve Phase – Roadmap & Objectives
• Identifying and selecting Process Improvement Solution
  • Generate Solutions
  • Benchmarking
  • Brainstorming/Modified Brainstorming
  • Solution Screening Tools
  • Solution Selection Matrix
• To-Be Process Map
• Financial Impact of Solutions
  • Cost/Benefit Analysis
• Validating / Testing Process Improvement Solution
  • Modeling
  • Simulation
  • Pilot Solution. Pilot Plan
• Process Risk Planning.
  • Potential Problem Analysis
  • Failure Mode and Effect Analysis (FMEA)
• Implementing Process Improvement Solutions
  • Implementation Plan
  • Stakeholder Management
  • Project Storyboard

IMPROVE – Practical Six Sigma Process Improvement Simulation

• 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
•  Implement your new process, measure the data and calculate improved sigma level.
• Run process again and measure data
  • Measure new processs
  • Draw control chart
  • calculate new sigma value (new process capability)

6 – Lean Six Sigma CONTROL Phase

• Control Phase – Roadmap & Overview
• Process Control. Process Charts for Managing the process
  • Run Charts. Responding to Special and Common Cause Variation
  • Control Charts. Control Limits vs. Specification Limits
• Process Monitoring Plan
  • Creating Processs KPI and Dashboards
  • Response Plan
• Project Documentation
  • Process Procedures
  • Solution Transfer Plan
• Solution Roll-out
• Project Closure
  • Lessons Learned

7 – Lean Six Sigma (DMAIC) Methodology Review

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

• Sa aplice metododolgia Lean Six Sigma pentru imbunatatirea proceselor utilizand DMAIC
• Sa participe eficient in echipe de proiect de tip Lean Six Sigma
• 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 metode de control ale proceselor de business

• Manageri de Proiect
• Sponsori, Project Owners, Management Executiv
• Manageri de Departamente: Marketing, Vanzari, Tehnic, Productie, R&D, HR, Financiar, Calitate
• Membrii echipelor de proiect care participa in proiecte de tip Six Sigma
• Persoane care doresc sa cunoasca abordarea Six Sigma

Nu sunt necesare cunostinte preliminare.