Duration
5 days
Introduction
This paper lays out the overall format of the Programme for the Six Sigma Management. On Completion of the first project the participant is really a Yellow Belt. However if the Project is implemented and the results audited by the financial department or by senior management for validity of achievement the team can be considered as a Green Belt. This certification can be done by the MD of the Company or a team of people selected by him.
Overall Course Content
- Current Improvement methods and Shortcomings
- What is the Six Sigma Philosophy?
- Benefits of Six Sigma
- The Strategic nature of Six Sigma
- Critical Success Factors of Six Sigma
- Organization for Six Sigma Implementation
- Management Role and Six Sigma training
- Master Black Belts and Black Belts
- Green Belts and Students belts
- Six Sigma Metric and its Analysis
- The Six Sigma Methodology (DMAIC)
- The Statistical Tools of Six Sigma (Toolkit)
- Data Collecting Tools
- Process mapping and other Tools
- Selecting Six Sigma Projects
- Measurement and Analysis of Process requirement Customer Satisfaction Measurement
- Measurement of Project Impact
- Conducting a Six Sigma Project
- Exercises and Simulation
- Working on Project
Schedule
Daily: 09.00 am – 17.00 pm
Morning Session: 09.00 – 12.45 pm
Morning Coffee Break: 10.30 am – 10.50 am
Lunch Break and Zohor: 12.45 pm - 0 14.00 pm
Afternoon Coffee Break: 15.30 pm – 15.40 pm
Course Outline
Theoretical Six Sigma Management
Day 1: Six Sigma Basics
What is Six Sigma Management
How to install Six Sigma
Project Selection
Day 2: Detailed DMAIC Method
Explanation in detail of the DMAIC Road Map
Basic Six Tools
Day 3: Quick Six Sigma Tools Explained
Note: Most Courses spend 14 days to study in detail the Six Sigma Statistical Tools. Here we will learn on the basic things about the tools and decide where and how to apply. Focus on hands on solving. Participants will be encouraged to bring lap top and use EXCEL Statistical Tools is they have computer. However the focus is you must know how to use the tool with hands and only then on computer
Practical Six Sigma Management:
Syndicate Work: Participants will work as a team on a practical project which may involve data collection. Project Work to gain confidence in the Six Sigma fieldwork: Project must be documented in the class.
Day 4: Application of Six Sigma Method to a Project
Completing the D – M Steps Actualized
Defining the Project parameter
Data Collection
Developing Project CTQs
Measuring the Sigma Value
Developing Templates to use in Plant.
Day 5: Application of Six Sigma Method to Project
Completing the A - I - C Steps Actualized
Analysis of Data
Developing Improvements and Plans for Implementation
Control Steps
Developing Templates to use in Plant for this step
Documentation and Presentation
Note 1: DMAIC Matrix
DMAIC Cycle Roadmap
Item
Step
Details
Target
DEFINE
Goals and targets and set specifications. Use the 5Ws1H Worksheet. Determining the Ys
and Xs of the selected process
Definition
MEASURE
Process characterization and establish baseline capability, Six Sigma measure, SPC tools are useful. Convert to money ($) the losses to be recovered by the
project.
Process Concretize
ANALYZE
The process variables and identify the vital few factors using the relevant Six Sigma Management
tools
Root Cause determined
IMPROVE
The process to reduce the
variation and cycle time, including errors. Take actions needed to
reduce the $ losses in the process
Exceed
Stretch Targets
CONTROL
The vital few factors and implement the process control system by laying out the control
plans and Risk Management
Maintain Control Plans
Note 2: The Tools Matrix
DMAIC CYCLE SIX SIGMA TOOL MATRIX
Item
Tools Most likely useful at the stage
DEFINE
Benchmarking, base lining, Kano Modeling, Voice of Customer, Voice of the business, Quality Function Deployment, Process Flow Mapping, Project Management, Management by Fact, Five Ws and 1 H,
Four What’s etc
MEASURE
7 Basic Tools of Quality Management, Defects metrics, data collection forms, plans, logistics,
sampling techniques, Control Charts, Voice of Process etc
ANALYZE
Cause and Effect diagrams, Failure Mode and Effect Analysis, Fault Tree Analysis, Failure trees, Statistical inferences, Control charts, Capability assessments, Reliability Analysis, Root cause analysis. Technical tools of Problem Solving, Why Why
analysis, systems thinking etc
IMPROVE
Correlation studies, Factor Analysis, Design of Experiments, Taguchi Parameter designs, Tolerances
Design, Robust Design principles
CONTROL
Control plans, control charts, time series, procedures adherence, Performance management, poka yokes and
prevention activities
Programme scope, delivery arrangements and suitability are confirmed during enquiry.