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Pivotal Resources - Continuous Improvement

 

Design for Six Sigma Training Agenda

The following is a typical Design for Six Sigma (DMADV) Training Agenda. Pivotal Resources can customize the course material to client training requirements, as well as certification objectives.

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Introduction

ACTIVITY: Team introductions, team name selection and get to know each other activity. (20 min)

  • Course Objectives, Agenda Review
Understanding Six Sigma
  • What and Why Six Sigma
  • Six Sigma Overview
    • Importance of Measurement
    • Terminology, Definition of Six Sigma
    • Six Sigma Strategies
    • Six Sigma Roadmap

 

Six Sigma Design Overview
  • How is Design Different?
  • The DMADV Model
  • Selected Design Tools
  • Design Conditions
  • Design Scenarios

 

Define
  • Create the Vision
    • Vision Ingredients
      ACTIVITY: Creating a vision. (20 min)
      ACTIVITY: Relations Diagram. (20 min)
      ACTIVITY: Change Readiness Assessment. (10 min)
    • Assumption Busting
      ACTIVITY: Assumption Busting. (25 min)
  • Develop Design Strategy and Charter
    • Multi-Generational Project Planning
      • Project phasing philosophies
    • Business Case
    • Opportunity Statement
    • Goal Statement
      ACTIVITY: Critiquing opportunity and goal statements. (30 min)
    • Constraints and Assumptions
    • Scope
    • Roles
    • Preliminary Plan
      ACTIVITY: Create rough draft project charters, select team roles and responsibilities. (45 min)
    • Building a Case for your Design Project
    • Force Field Analysis
      ACTIVITY: Create an elevator speech. (25 min)
    • Change Management/Stakeholder Analysis
      ACTIVITY: Perform a stakeholder analysis. (45 min)
    • Building a Case for your design project
  • Gather Voice of the Customer Data
  • Effectiveness Assessment
    • Understanding customer requirements
    • Kano analysis
  • Sources of CTQs
    • Customer research methods
      ACTIVITY: Discuss current VOC techniques. (20 min)
    • Organizing VOC input
    • Translating VOC into requirements
      • Affinity analysis, tree diagram. multivoting
        ACTIVITY: Analyzing customer needs.
  • Identify Initial Design Requirements
    • Conjoint analysis
      ACTIVITY: Conjoint analysis. (20 min) [optional]
    • Quality Function Deployment
      • House of Quality
      • Benefits
        ACTIVITY: QFD Rooms 1, 2, & 3. (20 min)
  • Clarify High-Level Process Structure
    • SIPOC Diagram
    • Design and process mapping
      ACTIVITY: Team discussion on best process map approach. (10 min)
      ACTIVITY: The pizza SIPOC. (10 min)
      ACTIVITY: List value-added, non-value-added and value-enabling activities from your knowledge of common business activities. (15 min)
  • Managing the Design Project
    • Teamwork checklist: vital signs
    • Components of good meetings
    • Teamwork management roles
    • Storyboards and tollgate reviews
  • Define Wrap-Up/Checklist Review

 

Measure
  • Measurement Concepts
  • Defining Measurement Objectives
    • Design (“greenfield”) vs. redesign
    • Deciding what and where to measure
      ACTIVITY: How’s your pizza process?
  • Prepare Definitions and Data Sources
    ACTIVITY: Defining a measure. (10 min)

    • Operational definitions
      ACTIVITY: Creating and testing operational definitions. (10 min)
    • Data sources and data collectors
    • Detailed process mapping
  • Create Initial Measurement Plan
    • Sampling: methods, strategies, situations, biases
    • Data types
    • Constructing and using data collection forms
      • Types of checksheets and examples
    • Preparing/training data collectors
  • Establishing Capability Baselines
    • Process capability (Cpl, Cpu, Cpk)
    • Defect measures (DPU, DPO, DPMO)
    • Performance scorecards
  • Validate Design Benefits
    • Cost of poor quality
    • Financial impact assessment
    • Benchmarks and best practices
  • Measure Wrap-up and Checklist Review
Analyze
  • Summary of Define and Measure
  • Analyze Challenges for Design/Redesign projects
  • Analyzing the Current Process
    • Value and cycle time analysis
  • Assess Process Interfaces
    • Interfaces & capability measures
    • Defining spec limits
  • Balancing & Refining Requirements
    • Performance vs. Satisfaction
    • Revisiting the House of Quality (Room 2 and 8)
  • Challenging Design Assumptions
    • Assumption Busting
    • TRIZ: Inventive problem solving
      • Addressing design contradictions
        ACTIVITY: Analyze Planning.
Design
  • Generating Design Ideas
    • Creating innovative ideas
    • Planning for brainstorming sessions
    • Brainstorming & advanced idea generation techniques
      ACTIVITY: Generating Ideas. (30 min)
    • Narrowing Ideas & Developing Ideas
      • Mixing, matching and combining ideas
      • Solution filtering: Pugh matrix
  • Designing New Processes
    • SIPOC (review)
    • “Should Be” process mapping
    • Workflow Design Opportunities
      • Organization Analysis
      • Deployment mapping
        ACTIVITY: Process Design. (90 min)
    • Key Design Decisions: Criteria Matrix
  • Refining the Design
    • “Talk-Through” and “Walk-Through”
      ACTIVITY: Talk-Through. (30 min)
    • Risk Management
    • Poke-Yoke: Mistake Proofing
      ACTIVITY: Risk Management. (45 min)
    • Costing the Process
      ACTIVITY: Process Costing. (30 min)
  • Plan & Test the Design
    • Process simulation and piloting
    • Sampling situations: Population vs. Process
      • Biases, strategies
    • Population Sampling Overview
      • Sample size calculations and worksheets
      • Sampling scenarios
    • Population Sampling Overview
      • Sample size calculations and worksheets
      • Sampling scenarios
    • Testing, Refining & Implementing Measurement
    • Consistency & stability
    • Design of Experiments (DOE)
      • Key terms, basic steps, assessing the results
        ACTIVITY: DOE opportunities. (20 min)
    • Capability Flow Down & Flow Up
  • Validating & Implementing the Design
    • Approvals & Buy-in
      ACTIVITY: Decisions and buy-in. (30 min)
    • Design Theme
      ACTIVITY: Elevator Speech/Theme. (30 min)
    • FMEA (Failure Modes and Effects Analysis)
      ACTIVITY: Identify two failure modes and note any possible changes to your design. (45 min)
    • Organizational analysis and implementation planning
  • Design Summary and Checklist
Verify
  • Planning Ongoing Measurement
    • SPC
    • Dashboards
    • Control Charts
      • Use and interpretation
      • Construction method
  • Developing Documentation
    • What to document and why
    • Revision planning for the process
      ACTIVITY: Documentation and control.
  • Process Management
    • Process Owner Responsibilities
    • Process Map
    • Monitoring
    • Response Plan
  • Verify Wrap-up and Checklist Review
  • Action Planning: Review, Conclusion and Next Steps

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