Introduction

• Getting Started: Introductions
  
  
• Key Outcomes
  
  
• Agenda Review
  
  
• Course Objectives

Six Sigma Overview

• What and Why Six Sigma
  • What is Six Sigma; a measure, a goal and a system
  • Key themes
  • Six Sigma roadmap
    
    
• Six Sigma Strategies
  • Benefits of Six Sigma
    
    
• Six Sigma Success Stories
  
  
• Six Sigma Success Factors
  • Proactive management
  • Customer focus
  • Process focus
  • Measures and data
  • Boundaryless collaboration
    
    ACTIVITY: Teams to discuss how they think Six Sigma can help in their organizations (30 min)
    
    
• Six Sigma Organization and Roles
  • Six Sigma structure
  • Roles and responsibilities
    
    
• DMAIC Process Overview
  • DMAIC Action Model
  • Advantages of DMAIC process

Define

• Identifying and Selecting Improvement Projects
  • Types of quality projects
  • Criteria for project selection
  • Prioritizing and selecting projects
    
    
• Defining the Project & Preparing a DMAIC Project Charter
  • Business Case
  • Problem/Opportunity statement
  • Goal statement
    
    ACTIVITY: Critiquing problem and goal statements (15 min)
    
    
  • Constraints and assumptions
  • Scope
  • Players and roles
  • Preliminary plan
    
    ACTIVITY: Create rough draft charter and select team roles and responsibilities for your project (30 min)
    
    
• Identifying the Customer and Process
  • Types of customers
  • Voice of the Customer data gathering
  • Understanding customer requirements
    
    ACTIVITY: Critiquing requirements (30 min)
    
    
  • Translating VOC into requirements
    
    ACTIVITY: Gathering VOC and stating requirements (20 min)
    
    
  • SIPOC model and process mapping
    
    ACTIVITY: Create a SIPOC (7 min)
    
    
  • Sub-process mapping
    
    ACTIVITY: Create a detailed process map for one sub-process within your project (35 min)
    

Measure

• Principles of measurement
  • Why measure?
  • Measurement plan
    
    
• Deciding What and Where to Measure
  • Identifying key output “Y” measures for the process
  • Measurement assessment
  • Types of measures
  • Stratification
    
    ACTIVITY: Develop key questions about your process and complete a measurement assessment (50 min)
    
    
• Operational definitions and Data Sources
  • Creating operational definitions
  • Identifying data Sources
    
    ACTIVITY: Calculate standard deviation (10 min)
    
    
• Sampling & Data Collection Forms
  • Sampling
  • Data collection forms
    
    ACTIVITY: Develop a sampling plan and data collection tools to be used for your project (60 min)
    
    
• Testing, Refining and Implementing Measurement
  
  
• Data Consistency and Stability
  
  ACTIVITY: Develop a measurement plan (35 min)
  
  
• Process Performance and Capability Measures
  • Defect Measures
    • Yield, Rolled Throughput Yield, Defects per unit, Defects per million opportunities
      
      ACTIVITY: Calculate, RTY and DPMO (25 min)
      
      
  • Process capability
  • Process dashboards and balanced scorecards

Analyze

• Process Analysis
  • Value/Non-value added analysis
  • Workflow principles and cycle time
    
    ACTIVITY: Complete a value and cycle time analysis (45 min)
    
    
• Data Analysis
  
  ACTIVITY: Practice exercise related to variation (5 min)
  
  
  • Pareto charts
  • Variation factors
  • Histograms
  • Run charts
  • Box plots
    
    ACTIVITY: Create Pareto and Run Charts (35 min)
    
    
• Considering Process Design/Redesign
  • Key differences
  • Benefits and challenges
  • Managing design/redesign
    
    
• Develop Root Cause Hypothesis
  • Developing hypotheses
  • Cause and effect
  • Comparative analysis and logical cause testing
    
    ACTIVITY: Work on root cause analysis for your project, formulate hypothesis, construct cause and effect diagram (45 min)
    
    
• Investigate and Verify Root Cause
  • Scatter diagrams
    
    ACTIVITY: Interpret scatter plots and determine correlation (10 min)
    
    
  • Correlation coefficients
  • Logical cause testing
  • Chi-square test
  • Cause verification
    
    ACTIVITY: Chi-square calculation (25 min)
    
    
  • Confidence testing

Introduction to Minitab [optional chapter]

Improve

• Generating Solution Ideas
  • Creating innovative ideas
  • Planning for brainstorming sessions
  • Brainstorming and advanced idea generation techniques
    
    ACTIVITY: Practice using advanced idea generation techniques to develop a list of potential solutions (20 min)
    
    
• Narrowing Ideas and Developing Proposed Solutions
  • Tools for solution filtering
  • "Should Be" process mapping
    
    
• Selecting the Best Solution
  • Cost Benefit Analysis
  • Criteria matrix (review)
    
    ACTIVITY: Mini-Case Study using criteria matrix (30 min)
    
    
  • Planning and Testing the Improvement Solution
  • Planning and project management
  • Piloting
    
    ACTIVITY: Prepare a piloting strategy based on case study (30 min)
    
    
  • Unintended consequences
  • Risk management
  • FMEA (Failure Modes and Effects Analysis)
    
    
    ACTIVITY: Practice using FMEA on proposed solution (30 min)
    
    
  • Mistake proofing
    
    
• Evaluating, Refining and Expanding Solutions
  • Implementation planning

Control

• Control Plan
  
  
• Planning Ongoing Measurement
  • Monitoring SIPOC
  • Dashboard review
  • Ongoing Measurement Tools
  • Control Charts
  • Use and interpretation
  • Construction methods
    
    ACTIVITY: Create a control based on predetermined data (15 min)
    
    
• Developing Documentation
  
  ACTIVITY: Understanding the importance of documentation (25 min)
  
  
  • Documentation Hints
    
    
• Preparing Revision and Response Plans
  
  ACTIVITY: Draft a sample control plan (7 min)
  
  
• Expanding the Gains & Concluding the Project
  • Institutionalization
  • Translating opportunities
  • Storyboards
  • Continuous improvement

Review and Conclusion