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: Goals & Metrics
- CTC, CTQ, CTS Parameters.
- CTx Flow-down Model (Big Y's, Little y's).
- Measurement & Feedback.
- Calculating Sigma Levels
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.
MEASURE: Establishing Process Baseline
- Enumerative vs. Analytic Statistics.
- Process Variation.
- Benefits of Control Charts.
- Requirements vs. Control.
- Control Chart Interpretation
MEASURE: Process Capability
- Histograms.
- Probability Plots.
- Goodness of Fit Tests.
- Capability & Performance Indices.
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: Regression Analysis
- Scatter Diagrams.
- Linear Model.
- Confidence & Prediction Limit
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
Design for Six Sigma Overview
- Methodology.
- Tools for DFSS
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