Duration

3 days

Overview

MTT Training represents the extensive study and exhaustive application of MTT and other process improvement techniques. MTT participants will plunge greater into the MTT methodologies and bring the participants to the level to steer project teams to achieve innovation business improvements for their organizations. This course will also emphasis on advanced statistical analysis and organizational change management.

MTT is a data-driven approach to problem solving, focusing on defect reduction and process improvement, resulting in cost savings. Projects are customer focused, using a team approach to resolve problems. The methodology follows a structured sequence of problem -solving techniques to arrive at a solution. Statistics aid in the decision-making process and help to validate the success of changes.

The Black Belt class will take you through the phases of MTT: Define, Measure, Analyse, Improve and Control. It will contain a blend of both Lean and MTT tools. The class is “hands on” in format using class projects and data within the scope of the classroom setting.

MTT who are seeking in-depth knowledge to advance their statistical abilities will have a considerable amount of hands-on practice in techniques such as SPC, MSA, Hypothesis Testing, Regression, DOE, sample calculation and many other MTTsuch as VSM, Set-up Time Reduction, Poka-Yoke, Visual Management, 5S, Layout Optimization and TPM.

By completing this course of study, you will gain a solid general knowledge of the theory, composition, and implementation of a Lean MTT initiative. You will also become proficient in all of the analytical tools necessary to define, measure, analyse, improve, and control Lean MTT improvement projects, including the design and analysis of general and fractional factorial experiments. You will learn team leadership and project management skills. In short, as a Black Belt you will master the skills necessary to lead a complex process improvement project that produces bottom-line results.

This workshop is designed for MTT team leaders and expands upon the skill set taught in the MTT. The coursework includes instruction on modules in practical DMAIC applications, Failure Mode Effects Analysis, Advanced Lean, Advanced DOE, SPC for non-normal distributions, Optimization, Scheduling & Sequencing, effective and efficient teamwork strategies, as well as a variety of other tools and analysis methodologies.

Learning Objectives

Gain thorough understanding of MTT and the DMAIC method
Identify areas where improvements can be made
Further develop skills to use analytics, mathematical models and design techniques
Decide on sampling strategies, sample size and confidence intervals
Describe the difference between long-term and short-term process capability
Characterize and optimize processes by computing and applying statistical techniques.
Develop and analyse control charts for both continuous and discrete data
Perform a measurement system analysis
Apply hypothesis tests to compare variance, means and proportions
Conduct regression and residual analyses
Design, simulate, and execute designed experiments that depict validated improvement.
Learn how to plan and implement process control to hold project gains

Benefits

Complete projects that result in measurable bottom-line improvement
Reducing variation / defects in any processes
Improved Customer Loyalty & Satisfaction
Embodies a disciplined, data-driven analytical approach
Create an improvement system with proven tools
Improve your most important asset: your employees
Achieve organizational excellence in business process improvement
Excellent return of investments
Complete projects that result in measurable bottom-line improvement
Improving market penetration and organizational speed
Increased price flexibility
Faster delivery time
Reduced Cycle Time
Employee Motivation & Satisfaction
Strategic Planning
Supply Chain Management
Improved communication (provides a common language
Increased quality and reliability

Course Outline

INTRODUCTION (DAY 1)

In-depth coaching on Lean MTT fundamentals and methodologies
Lean MTT project selection criteria
Capturing the relationship among different business entities including internal and external impacts

LEADERSHIP & COACHING (DAY 1)

Identifying different roles that influences decision making, resources, supporting pillars
Eliminating potential roadblocks in the process of getting green light for project execution.
Dealing with difficult team members
Putting in strategic planning for deployment

PROJECT MANAGEMENT(DAY 1)

Understand and progress a structure for project realization
Stakeholder management
Developing the essential resource management such as human capital, finance, etc.
Project monitoring and control

DEFINE BUDGETTING(DAY 2)

Bringing the customer needs into perspective (VOC – identify, data collection, requirement listing, S CURVE)
Aligning the project scoping (Project charter – business case, problem statement, goals, SMART, project timeline, measurements, data analysis Using Capex vs Opex)

LEAN MANUFACTURING (DAY 2)

Fetching critical data that impacts selected project (Fishbone diagram, takt time, cycle time, work in progress, etc)
Selection of process analysis tools for data gathering (mapping, charts, diagrams, etc)
Define, categorize and plan for data collection methods (check sheets, data collection plan, sampling, etc)
Measurement systems and statistics (MSA, graphical analysis, capability analysis (Cp, Cpk), etc)

LEAN SIGMA(DAY 2)

Identify methods and tools to interpret collected data
Analyse and interpret the correlation between variables (regression, central theorem, ANOVA, etc)
Determine the significance of hypothesis testing (type of errors, variances, parametric, non-parametric tests, etc)
Non normal data handling
Hands-on with Minitab software for data analysis (Chi-Square, t-test, boxplot, pareto chart, etc)

KAIZEN (DAY 3)

Generating ideas (brainstorming, out of the box thinking)
Designing/planning experiments to determine the objectives, responses and outcome of the test (DOE, sample size, randomization, etc)
Identify and eliminate waste techniques (Kaizen, Kanban, Poka Yoke, etc)
Solution risk assessment (FMEA)
Running pilot testing

7 QC TOOLS & POKA YOKE (DAY 3)

Putting in controls for monitoring improvement (SPC, control charts, TPM, etc)
Introducing visual management elements
Documentation development for sustaining improvement (control plan, SOPs, etc)
Establish training for knowledge transfer to process owners
Balanced scorecard (Benefits realization)
Handover (SOP, FMEA, compliance etc…)
Recognition and project closure

Pre-requisite

Already being trained or some basic knowledge on the following course subjects:

a) Basic Problem-Solving Technique using the 7 Basic QC Tools.

b) DIPLOMA AND DEGREE HOLDERS

c) Familiar with Project Management Fundamentals

Methodology

Facilitation with Theory, Lecture and Discussions
Identify Projects for improvement for Quality, Cost and Delivery using Case Study

Target Participants

All personnel including Managers, Engineers, Supervisors & Technicians

Programme scope, delivery arrangements and suitability are confirmed during enquiry.

MANAGEMENT TOOLS & TECHNIQUES