Day 1 | Time | Topic | Objective | Practical Exercises |
8:30 AM | Introduction | ProcessQM Intro. Review Course and introduce students and Instructor | ||
9:00 AM | History of Lean and Six Sigma | Understand the origins and background for Lean and Six Sigma | ||
10:45 | Break | |||
11:00 AM | Managing Lean Six Sigma Projects | Overview of Project Management Principles | ||
12:00 | Lunch | |||
1:00 | Basic Statistics | Have a basic knowledge of probability– | Coin Toss exercise | |
2:30 | Break | |||
2:45 | Understand the differences of Central Tendency Measures (Mean, Mode, Median) | Calculate each of the measures on a set of data from Coin Toss exercise | ||
3:30 | Understand variation and Standard Deviation (Sigma) | Calculate Standard Deviation from Coin Toss and additional set of data | ||
4:15 | Understand the difference between Discrete and Continuous Data | |||
4:45 | Review | Review material and prepare for tomorrow | Oral Quiz/Review | |
Day 2 | 8:30 | Lean Principles and typical Kaizen event | Understand Lean principles and understand how to conduct a typical Kaizen event | |
9:00 | Value
| Understand value to the customer | Exercise for what a customer is willing to pay for a hamburger | |
9:30 | Waste (Muda)
| Understand the eight wastes in Lean | ||
10:00 | Speed and flow—Single piece vs batch | Understand speed and flow in the process and the benefits of single piece vs batch processing | Batch Exercise with card stock. Build a Spaghetti Diagram for getting ready for work in the morning. | |
10:30 | Break | |||
10:45 | Balanced delivery (Tackt Time) | Understand the concept of balanced delivery | Calculate tackt time from example | |
11:15 | Kanban (Pull and Just in Time) | Understand the concept of pull and Just in Time delivery in a Lean system | ||
11:30 | Standard Work | Understand the concept of Standard Work | Create a standard work template | |
12:00 | Lunch | |||
1:00 | No defects | Understand the concept of no defects in the process | ||
1:15 | Gemba | Understand what Gemba is and what it means | ||
1:30 | Kaizen | Understand what Kaizen means and how it applies to Lean | ||
1:45 | 5S Tool | Understand and describe the 5 steps in the 5S tool | ||
2:15 | Break | |||
2:30 | Kaizen Event | Describe 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 | |||
4:30 | Review | Review today’s material and prepare for tomorrow | Oral Quiz | |
Day 3 | 8:30 | Six Sigma–Define | Describe the Define Phase of SS and the tools used in this section | |
9:00 | Describe what a Problem Statement is and some of the pitfalls and guidelines
| Create a problem statement for a project | ||
9:45 | Define your customers and what they need. Discuss Critical to Quality. | |||
10:15 | Break | |||
10:30 | Understand and define the critical elements of a project Charter | Create a draft charter for the SS project | ||
11:30 | Understand the elements of SIPOC Diagram
| SIPOC | ||
12:00 | Map the Process | |||
12:15 | Lunch | |||
Six Sigma-Measure | Understand and describe what must be done in the measure phase | |||
1:15 | Review types of data from Day 1. Discrete Continuous
| |||
1:45 | Describe how to measure data Population Sample Consistency/ Repeatable
| Tool: Build a Data Sheet Complete a Gage R& test? | ||
2:45 | Break | |||
3:00 | Understand how to determine what to measure | |||
3:30 | Understand and determine how much Data you need? | |||
4:00 | Understand and determine how to show the results of your data | Statistical graphs (Bar, Pie, Line) | ||
4:30 | Review | Oral review of today’s topics and prepare for tomorrow’s class | Oral Quiz | |
Day 4 | Six Sigma–Analyze | Understand how to analyze the data measured to find Root Cause | ||
8:30 | Overview of Analyze | Understand the Analyze phase | ||
9:00 | Interpret Data | Understand and determine the correct tools to use to interpret the data | Build Histogram Build Pareto Chart Build Scatter Diagram (Correlation)
| |
10:30 | Break | |||
10:45 | Interpret Data | Understand and determine the correct tools to use to interpret the data | Build Control Chart
Review Bar, Pie, and Line graphs Discuss Interrelationship Diagram
| |
Time | Topic | Objective | Practical Exercises | |
12:00 | Lunch | |||
1:00 | Determine Root Cause | Understand root causes and the tools to use to determine | Build Ishikawa Diagram (FishBone) Build 5 whys chart | |
2:30 | Break | |||
2:45 | Identify Opportunities for Improvement | Identify areas for improvement identified in the root cause analysis | ||
Six Sigma–Improve | Understand how to select a solution based on root cause analysis | |||
3:15 | Select solution | Understand how to select a solution using brainstorming and FMEA tool | Create a FMEA | |
4:30 | Review | Review material and quiz | Oral Quiz | |
Day 5 | 8:30 | Select solution | Understand how to select a solution using the Pair Wise ranking and Solution Weighting Tool. | Build Solution Weighting tool with possible options |
9:30 | Test and validate Solution | Understand how to set up a test plan and then to measure the success using hypothesis testing | Create a test plan and run hypothesis test to ensure success | |
Six Sigma–Control | Understand what needs to be done to control the process changes and ensure sustain the gain | |||
9:30 | Shift and Drift | Understand that there is normal movement of processes. | ||
9:45 | Mistake Proof the Process | Understand methods to mistake proof a process so it can only be done one way | ||
10:15 | Break | |||
10:30 | Metrics and controls | Understand and explain the types of metrics needed to maintain the changes and identify when there is a shift in the process | Exercise to develop different types of metrics | |
11:30 | Audits and inspections | Understand the role of audits and how often they should be done | ||
12:00 | Lunch | |||
1:00 | Documenting new processes and procedures | Understand how to document new processes in SOPs and revised process maps | ||
1:30 | Visual boards and metrics tracking | Understand the importance of visually tracking metrics and results to sustain the gain | ||
2:00 | Course Survey | Complete Course Survey | Course Survey | |
2:15 | Review material and Test | Review today’s material and take overall test for comprehension and understanding
| Oral Quiz
Written Course Test |