This course will suit anyone who needs a thorough understanding of what Lean Six Sigma is and how it works in practice. The course includes a practical introduction and training on the full range of Lean Six Sigma tools. On completion of this course delegates will be able to work as leaders of Lean Six Sigma DMAIC projects. This course has proved to be equally relevant to manufacturing and service/transactional environments. The mix of delegates on the training is one of the attractions of attending this open programme. No prior knowledge or experience is required. Each participant receives a comprehensive delegate pack including Catalyst's Lean Six Sigma Improvement Toolbook, Statistical Tool guides, Worksheets, Project examples and support materials for use in Minitab.
This programme includes training on the advanced (statistical) tools required to execute the full range of Lean Six Sigma DMAIC projects. Practical exercises are incorporated to provide relevant scenarios for delegates. During these modules each delegate will be required to use statistical software. We use MINITAB™ Statistical Software in our training. No prior knowledge of Minitab is needed. A full practical introduction is included at the start of the programme. Delegates will need to bring a laptop computer.
Curriculum
The course begins with a 1 day Lean Six Sigma Awareness Workshop (optional).
Lean Six Sigma Foundation (4 days) introduces the Lean Six Sigma principles and methodology. Delegates then cover the Define, Measure, Analyse, Improve, Control [DMAIC] phases in depth including: change management; project definition; charters; stakeholder analysis; process mapping; voice of the customer; Critical-To-Quality (CTQ); input/output measures; data collection; control charts; root cause analysis and basic non-statistical tools. Lean techniques including Value Stream Maps, 5S, Flow are integrated into the programme to show how the two approaches can work together and complement each other. Several individual and team exercises are used to reinforce the concepts and encourage use of the tools.
Change Management (3 days) covers the “softer” change management tools required to lead successful Lean Six Sigma projects. Topics included in this 3-day module include change management, team building, and conflict resolution. This module is delivered through a combination of presentation, case studies, videos and hands-on exercises.
Stats Tools 1 (3 days) topics include an Introduction to MINITAB™ software followed by Normality (Central Limit Theorem, P-values, Transforming Data), Sampling (Random and Process Sampling, Determining Sample Sizes, Selecting Samples), Measurement System Analysis (Data Types, Gauge R&R, Attribute Agreement Analysis) and Introduction to Hypothesis Tests (Z- and t-tests).
Stats Tools 2 (3 days) topics include Hypothesis Tests (Analysis of Variance and Chi-Square Tests), Regression (Simple, Multiple, Binary Logistic), Control Charts (Continuous and Attribute Data Charts), Process Sigma (Short- and Long-Term Sigma, Determining Process Shift, Improvement Strategies) and an introduction to Designed Experiments (Full and Fractional Factorial Designs).
Black Belt Advanced Tools (3 days) covers more advanced statistical analysis tools. This module will begin with a challenging case study that will take the delegates from initial project charter development through a designed experiment. Subsequent advanced training in regression analysis (with indicator variables, curvilinear regression and logistic regression), hypothesis testing (non-parametric), control charts (non-Shewhart) and Design of Experiments (Taguchi) complete this module.
Lean Six Sigma for Innovation and Design
Objectives
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Empower yourself to be more effective in creating the future of your organisation
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When to apply DMADV versus the DMAIC process?
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Understand the DMADV process and the tools you can apply to your projects
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Design and tollgate reviews and how these reviews should be conducted and managed
“The best way to predict the future is to create it.”
Peter F. Drucker, American Management Guru
So Why and How Does Lean Six Sigma help? The Lean Six Sigma Innovation and Design Journey
Day 1
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Introductions and Objectives
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Importance of Innovation and DMAIC vs DMADV?
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Change Management
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DEFINE: Segmenting Customers and Multi-Generation Planning
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MEASURE: VOC techniques and issues
Day 2
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QFD, creating the ‘House of Quality’
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CTQs and rating needs, Competitive and Benchmark assessment
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Value Proposition and Design Scorecards
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ANALYSE: Functional Analysis, Transfer Functions and HOQ2
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Concept Development and Testing
Day 3
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Design Elements and High Level Design
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Capability Evaluation, Modelling and Risk
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DESIGN: Detailed Design and Design of Experiments
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Design Integration and Pilot planning
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VERIFY: Piloting and Implementation
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Control, Process Management, Transition and Closing
Supported by lots of exercises and discussion breaks.
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