Module 1: Introduction to Six Sigma

• History of Quality (Deming, Juran, JIT, Ishikawa, Taguchi, etc.)
• Evolution of Six Sigma
• Defining Six Sigma – philosophy and objectives
• Overview of Six Sigma DMAIC process

Module 2: Stakeholders & Setting up a Six Sigma Project

• Identifying and Documenting stakeholder requirements
  • Identifying stakeholders and customers
  • Data collection and analysis
  • Determining critical requirements
• Project Selection Criteria
  • Identifying performance metrics
  • Using Financial criteria to evaluate project benefits
  • Maximizing project benefits for the organization
• Project Planning
  • Creating Project Charter
  • Charter Negotiation
• Managing Team Dynamics
  • Initiating teams
  • Stages of team evolution
  • Maslow’s hierarchy of needs
  • Motivation Techniques
  • Conflict Resolution Techniques
  • Management / Leadership styles
  • Roles played by people in a project
• Important project management & planning tools

Module 3: Six Sigma Methodology – Define

• Inputs – Need for six sigma project, Executive management sponsorship, core team identified
• Tools
  • Organization hierarchy
  • High level process maps
  • High level Pareto charts
  • Idea generation and categorization tools
• Outputs
  • Project charter
  • Established metrics
  • Problem statement
  • Roles & responsibilities

Module 4: Six Sigma Methodology – Measure

• Objectives of Measure Phase
• Inputs – the outputs of the Define phase
• Tools
  • Data collection tools and techniques
  • Measurement scales
  • Validation techniques (Gauge R & R)
  • Statistical distributions
  • Data mining
  • Run charts
  • Process map
  • Stakeholder tools
  • Process costs
• Outputs
  • Well defined processes
  • Baseline process capability
  • Process parameters affecting CTQs
  • Cost of poor quality (COPQ)
  • Measurement system

Module 5: Six Sigma Methodology – Analyze

• Objectives of Analyze Phase
• Inputs – outputs of the Measure phase
• Tools
  • Ishikawa diagram
  • Failure mode and effects analysis
  • Hypothesis testing
  • Process capability study
• Outputs
  • Important causes of defects
  • Special and common causes of variation
  • DPMO and sigma level

Module 6: Six Sigma Methodology – Improve

• Objectives of Improve Phase
• Inputs – outputs of the Analyze phase
• Tools
  • Returns on investment
  • Solution design matrix
  • Design of experiment
  • Taguchi robustness concepts
  • Response surface methodology
  • Project planning and management tools
  • Prototypes
• Outputs
  • Cost / benefit for different solution
  • Selection of solutions for implementation
  • Implementation plan

Module 7: Six Sigma Methodology – Control

• Objectives of Control Phase
• Inputs – outputs of the Improve phase
• Tools
  • Control plan
  • Statistical process control
  • Lean enterprise
  • 5S
  • Kaizen
  • Kanban
  • Total productive maintenance
  • Measurement system reanalysis
• Outputs
  • Implemented solutions
  • Revised measurement system
  • Control plan for sustaining benefits
  • Improves process capability
  • Lessons learned

Module 8: Lean

• A Value Stream Map
• Lean is Speed
• Total Supply Chain
• Lean Six Sigma Logistics

Case Study

• Case Study Part 1
• Case Study Part 2
• Case Study Part 3