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Introduction

• Welcome & Introductions
  
  
• Workshop Objectives & Agenda

What is Six Sigma?

• A MEASURE of process capability
  
  
• A GOAL for meeting customer requirements efficiently
  
  
• A SYSTEM for sustained business success with three core elements:
  • Customer Focus
  • Process Management
  • Facts & Data - variation & processes
    
    
• Key tools and methods
  
  
• Six Sigma Strategies
  • Process Improvement
  • Process Design/Redesign
  • Process Management
    
    
• The DMAIC improvement model – overview

Why Six Sigma?

• Changing business habits: Threshold of Pain
  
  
• The Six Sigma Roadmap – overview
  
  
• Six Sigma Case Histories
  
  
• Benefits for the Bottom-Line
  • Increase understanding of customers
  • Increase effectiveness
  • Enhance efficiency
  • Transform management

How to Establish Six Sigma Infrastructure

• Six Sigma Roadmap Overview
  
  
• Leadership Structure and Roles Overview
  • Executive / top leader
  • Champion / Sponsor
  • Team Leader – Black Belt
  • Team Member – Green Belt
  • Process Owner
  • Coach – Master Black Belt
    
    
• ROADMAP STEP 1 – Identify Core Processes & Key Customers
  • Core and Enabling relationships
    
    ACTIVITY: Identify Core Processes.
    
    
• ROADMAP STEP 2 – Define Customer Requirements
  • What are "requirements?"
  • Six Sigma and the Customer
    • Strategic Emphasis on Customer Knowledge
  • Listening to the Customer
    • "Traditional" and "New Generation" methods
  • Guidelines for defining requirements
    
    
• ROADMAP STEP 3 – Measure Defects / Baseline Performance
  • What is a measure? Examples.
  • Measurement Roadmap
  • Selecting What / Where to Measure
  • "Operational Definition"
    
    ACTIVITY: Creating operational definitions.
    
    
• Defect Measures and Calculations
  • Proportion Defective: Fraction of defective units
  • Final Yield: Error-free units
  • DPU: Defects/unit
  • DPO: Defects/opportunity
  • DPMO: Defects/million opportunities
  • Rolled Throughput Yield

Selecting & Executing Improvement Projects

• Identifying, prioritizing and selecting projects
  • Types of projects
  • Sources of ideas
  • Scaling and scoping
  • Financial impact and selection criteria
    
    ACTIVITY: Draft list of potential projects.
    
    
• Define: Setting up the Six Sigma Project
  • Define roadmap and overview
  • Quality Function Deployment (QFD)
  • Charter: Business Case, Problem & Goal Statements
    
    
• Measure: Validating the Problem; Tracking the Process
  • Measure roadmap and overview
  • Measurement selection and data types
  • Operational definitions
  • Sampling: biases, strategies, stratification, sample sizes
    
    
• Analyze: Understanding the Cause
  • Analyze roadmap and overview
  • Process analysis
  • Data display and analysis tools, cause and effect
  • Choosing Design/Redesign vs. Improvement
    
    
• Improve: Develop and Implement Solutions
  • Improve roadmap and overview
  • "Assumption busting"
  • Solution screening, piloting
  • Design of Experiments (DOE)
  • Process Design/Redesign: options
  • Failure modes and effects analysis (FMEA)
  • Poke-yoke: Mistake proofing
    
    
• Control: Sustain Solutions
  • Control roadmap and overview
  • Monitoring and control
  • Balanced scorecards and process dashboards
    

Planning for Six Sigma

• Six Sigma Start-Up Checklist
  • Building a case for Six Sigma
    
    
• Preparing for a change effort (R = Q x A)
  • R – results
  • Q – quality of results
  • A – acceptance by the organization
    
    ACTIVITY: Elevator speech.
    
    
• Key implementation decisions
  • Objectives
  • Activities and projects
  • Roles and structure
  • Pace and scale of roll-out
  • Budgets and resources
    
    ACTIVITY: Next Steps & Responsibilities.