Course Outline for LSSGB Training

Day 1TimeTopicObjectivePractical Exercises
8:30 AMIntroductionProcessQM Intro. Review Course and introduce students and Instructor
9:00 AMHistory of Lean and Six SigmaUnderstand the origins and background for Lean and Six Sigma
10:45Break
11:00 AMManaging Lean Six Sigma ProjectsOverview of Project Management Principles
12:00Lunch
1:00Basic StatisticsHave a basic knowledge of probability–Coin Toss exercise
2:30Break
2:45Understand the differences of Central Tendency Measures (Mean, Mode, Median)Calculate each of the measures on a set of data from Coin Toss exercise
3:30Understand variation and Standard Deviation (Sigma)Calculate Standard Deviation from Coin Toss and additional set of data
4:15Understand the difference between Discrete and Continuous Data
4:45ReviewReview material and prepare for tomorrowOral Quiz/Review
Day 28:30Lean Principles and typical Kaizen eventUnderstand Lean principles and understand how to conduct a typical Kaizen event
9:00Value

 

Understand value to the customerExercise for what a customer is willing to pay for a hamburger
9:30Waste (Muda)

 

Understand the eight wastes in Lean
10:00Speed and flow—Single piece vs batchUnderstand speed and flow in the process and the benefits of single piece vs batch processingBatch Exercise with card stock.

Build a Spaghetti Diagram for getting ready for work in the morning.

10:30Break
10:45Balanced delivery (Tackt Time)Understand the concept of balanced deliveryCalculate tackt time from example
11:15Kanban (Pull and Just in Time)Understand the concept of pull and Just in Time delivery in a Lean system
11:30Standard WorkUnderstand the concept of Standard WorkCreate a standard work template
12:00Lunch
1:00No defectsUnderstand the concept of no defects in the process
1:15GembaUnderstand what Gemba is and what it means
1:30KaizenUnderstand what Kaizen means and how it applies to Lean
1:455S ToolUnderstand and describe the 5 steps in the 5S tool
2:15Break
2:30Kaizen EventDescribe how a week-long Kaizen Event is conducted
-Overview/training

-Map the process with a value stream map (walk the process, time steps identify inventory,

identify wait time, identify errors

-Identify opportunities for improvement (Brainstorming and Affinity Diagram)

-Identify solutions

-Implement solutions

-Measure results

-Document and Implement results

 

Build Value Stream Map

 

 

 

 

 

 

Participate in an Affinity Diagram Exercise

4:30ReviewReview today’s material and prepare for tomorrowOral Quiz
 
Day 38:30Six Sigma–DefineDescribe the Define Phase of SS and the tools used in this section
9:00Describe what a Problem Statement is and some of the pitfalls and guidelines

 

Create a problem statement for a project
9:45Define your customers and what they need.  Discuss Critical to Quality.
10:15Break
10:30Understand and define the critical elements of a project CharterCreate a draft charter for the SS project
11:30Understand the elements of  SIPOC Diagram

 

SIPOC
12:00Map the Process
12:15Lunch
Six Sigma-MeasureUnderstand and describe what must be done in the measure phase
1:15Review types of data from Day 1.                                    Discrete                            Continuous

 

1:45Describe how to measure data

Population

Sample

Consistency/   Repeatable

 

Tool:  Build a Data Sheet

Complete a Gage R& test?

2:45Break
3:00Understand how to determine what to measure
3:30Understand and determine how much Data you need?
4:00Understand and determine how to show the results of your dataStatistical graphs (Bar, Pie, Line)
4:30ReviewOral review of today’s topics and prepare for tomorrow’s classOral Quiz
Day 4Six Sigma–AnalyzeUnderstand how to analyze the data measured to find Root Cause
8:30Overview of AnalyzeUnderstand the Analyze phase
9:00Interpret DataUnderstand and determine the correct tools to use to interpret the dataBuild Histogram

Build Pareto Chart

Build Scatter Diagram (Correlation)

 

10:30Break
10:45Interpret DataUnderstand and determine the correct tools to use to interpret the dataBuild Control Chart

 

Review Bar, Pie, and Line graphs

Discuss Interrelationship Diagram

 

TimeTopicObjectivePractical Exercises
12:00Lunch
1:00Determine Root CauseUnderstand root causes and the tools to use to determineBuild Ishikawa Diagram (FishBone)

Build 5 whys chart

2:30Break
2:45Identify Opportunities for ImprovementIdentify areas for improvement identified in the root cause analysis
Six Sigma–ImproveUnderstand how to select a solution based on root cause analysis
3:15Select solutionUnderstand how to select a solution using brainstorming and FMEA toolCreate a FMEA
4:30ReviewReview material and quizOral Quiz
 
Day 58:30Select solutionUnderstand how to select a solution using the Pair Wise ranking and Solution Weighting Tool.Build Solution Weighting tool with possible options
9:30Test and validate SolutionUnderstand how to set up a test plan and then to measure the success using hypothesis testingCreate a test plan and run hypothesis test to ensure success
Six Sigma–ControlUnderstand what needs to be done to control the process changes and ensure sustain the gain
9:30Shift and DriftUnderstand that there is normal movement of processes.
9:45Mistake Proof the ProcessUnderstand methods to mistake proof a process so it can only be done one way
10:15Break
10:30Metrics and controlsUnderstand and explain the types of metrics needed to maintain the changes and identify when there is a shift in the processExercise to develop different types of metrics
11:30Audits and inspectionsUnderstand the role of audits and how often they should be done
12:00Lunch 
1:00Documenting new processes and proceduresUnderstand how to document new processes in SOPs and revised process maps
1:30Visual boards and metrics trackingUnderstand the importance of visually tracking metrics and results to sustain the gain
2:00Course SurveyComplete Course SurveyCourse Survey
2:15Review material and TestReview today’s material and take overall test for comprehension and understanding

 

 

 

Oral Quiz

 

Written Course Test