Why Do Six Sigma?
- Definition and graphical view of Six Sigma
- Overview of business applications
- Example Sigma Levels
- Introduction to DPMO and cost as metrics.
- Comparisons between typical TQM and Six Sigma Programs.
- Origins and Success Stories.
How to Deploy Six Sigma?
- Leadership responsibilities.
- Description of the roles and responsibilities.
- Resource allocation.
- Data driven decision making.
- Organizational metrics and dashboards
Six Sigma Projects
- Project Focus.
- Selecting Projects.
- Overview of DMAIC methodology.
- Project Reporting
Incorporating Voice of the Customer
- Kano.
- Customer Focus and the Leadership Role.
- Customer Data.
- Big Y's, Little Y's.
DEFINE: Project Definition
- Tasks.
- Pareto Diagrams.
- Process Maps.
- Matrix Diagrams.
- Project Charters.
- Reporting.
DEFINE: Project Financials
- Quality Cost Classifications.
- Quantifying Project Benefits.
- Calculations.
DEFINE: Goals & Metrics
- CTC, CTQ, CTS Parameters.
- CTx Flow-down Model (Big Y's, Little y's).
- Measurement & Feedback.
- Calculating Sigma Levels
DEFINE: Project Scheduling
- Activity Network Diagram.
- PERT Analysis. (Optional)
- GANNT Chart.
DEFINE: Change Management / Teams
- Problems with Change.
- Achieving Buy-In.
- Team Formation, Rules & Responsibilities.
- Stages of Team Development.
- Overcoming Problems.
- Consensus Building
- Affinity Diagram.
- Nominal Group Technique.
- Prioritization Matrix.
MEASURE: Tools
- Measure Stage Objectives
- Flowcharts.
- Process Maps.
- SIPOC.
- Box-Whisker Plots.
- Cause & Effect Diagrams.
- Check Sheets.
- Interrelationship diagrams
MEASURE: Establishing Process Baseline
- Enumerative vs. Analytic Statistics.
- Process Variation.
- Benefits of Control Charts.
- Requirements vs. Control.
- Control Chart Interpretation
MEASURE: X-Bar Cha. Uses
- Construction & Calculations.
- Assumptions.
- Rational Subgroups.
- Sampling Considerations.
- Interpretation.
MEASURE: Individuals Data
- Uses.
- Construction & Calculations.
- Assumptions.
- Sampling Considerations.
- Interpretation.
- Overview of Other Individual Charts.
- Run Charts.
- Moving Average Charts.
MEASURE: Process Capability
- Histograms.
- Probability Plots.
- Goodness of Fit Tests.
- Capability & Performance Indices.
- Relative to Process Control.
- Interpretation.
- Estimating Error.
MEASURE: Attribute Charts
- Uses.
- Selection.
- Construction & Calculations.
- Sampling Considerations
MEASURE: Short Run SPC
MEASURE: Measurement Systems Analysis
- Stability Studies.
- Linearity Analysis.
- R&R Analysis.
- Range Method Calculations.
- Interpretation.
- Using Control Charts.
- Destructive Tests.
- ANOVA Method.
ANALYZE: Lean Thinking
- Definition of Waste.
- Analyzing Process for NVA.
- Cycle Efficiencies
- Lead Time and Velocity
- Methods to Increase Velocity.
- Standardization
- Optimization
- Spaghetti Diagrams (Optional)
- 5S
- Level Loading.
- Flow
- Setup Reductions
ANALYZE: Sources of Variation
- Multi-vari Plots
- Confidence Intervals on Mean
- Hypothesis Test on Mean
- Hypothesis Test on Mean of Two Samples
- Power & Sample Size.
- Contingency tables.
- Chi-Square Tests
- Non-parametric Tests.
ANALYZE: Regression Analysis
- Scatter Diagrams.
- Linear Model.
- Confidence & Prediction Limit
ANALYZE: Multiple Regression
- Multiple Regression with Attribute Xs.
- Multivariate Models.
- Interaction Plots.
- Interpreting ANOVA Tables.
- Model Considerations.
- Stepwise Regression.
- Residuals Analysis.
ANALYZE: DOE Introduction
- Terminology
- DOE vs. Traditional Experiments
- DOE vs. Historical Data
- Design Planning.
- Design Specification.
- Selecting Factors and Levels.
- Complete Factorials.
- Fractional Factorials.
- Aliasing.
- Screening Designs.
IMPROVE: DOE Analysis Fundamentals
- Estimating Effects and Coefficients.
- Significance Plots.
- Estimating Error.
- Extending Designs.
- Power of Design.
IMPROVE: Design Selection
- Desirable Designs.
- Performance.
- Balance.
- Orthogonality.
- Resolution.
- Other Design Models.
- Saturated Designs.
- Plackett Burman Designs.
- Taguchi Designs (mention).
IMPROVE: Tools
- Improve Stage Objectives.
- Tools to Prioritize Improvement Opportunities.
- Tools to Define New Process Flow.
- Lean Tools to reduce NVA and Achieve Flow.
- Tools to Define & Mitigate Failure Modes.
- PDPC. (Optional)
- FMEA.
- Preventing Failures.
- Reference to Tools for Defining New Process Levels.
CONTROL: Tools
- Control Stage Objectives.
- Control Plans.
- Training.
- Measuring Improvement
CONTROL: Charts
- X Bar-R, IMR
- P, np charts.
- C, u Charts
- Other types of control charts
Design for Six Sigma Overview
- Methodology.
- Tools for DFSS
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