Lean Six Sigma Green Belt Training Agenda

Introduction

Lean Six Sigma Overview

What and Why Lean Six Sigma
- What is Lean Six Sigma; a measure, a goal and a system
- Key themes
- Lean Six Sigma roadmap
Lean Six Sigma Strategies
- Benefits of Lean Six Sigma
Lean Six Sigma Success Stories
Lean Six Sigma Success Factors
- Proactive management
- Customer focus
- Process focus
- Measures and data
- Boundaryless collaboration
  
  ACTIVITY: Teams to discuss how they think Lean Six Sigma can help in their organizations (30 min)
Lean Six Sigma Organization and Roles
- Lean Six Sigma structure
- Roles and responsibilities
DMAIC Process Overview
- DMAIC Action Model
- Advantages of DMAIC process

Define

Identifying and Selecting Improvement Projects
- Types of quality projects
- Criteria for project selection
- Prioritizing and selecting projects
Defining the Project & Preparing a DMAIC Project Charter
- Business Case
- Problem/Opportunity statement
- Goal statement
  
  ACTIVITY: Critiquing problem and goal statements (15 min)
- Constraints and assumptions
- Scope
- Players and roles
- Preliminary plan
  
  ACTIVITY: Create rough draft charter and select team roles and responsibilities for your project (30 min)
Identifying the Customer and Process
- Types of customers
- Voice of the Customer data gathering
- Understanding customer requirements
  
  ACTIVITY: Critiquing requirements (30 min)
- Translating VOC into requirements
  
  ACTIVITY: Gathering VOC and stating requirements (20 min)
- SIPOC model and process mapping
  
  ACTIVITY: Create a SIPOC (7 min)
- Sub-process mapping
  
  ACTIVITY: Create a detailed process map for one sub-process within your project (35 min)

Measure

Principles of measurement
- Why measure?
- Measurement plan
Deciding What and Where to Measure
- Identifying key output “Y” measures for the process
- Measurement assessment
- Types of measures
- Stratification
  
  ACTIVITY: Develop key questions about your process and complete a measurement assessment (50 min)
Operational definitions and Data Sources
- Creating operational definitions
- Identifying data Sources
  
  ACTIVITY: Calculate standard deviation (10 min)
Sampling & Data Collection Forms
- Sampling
- Data collection forms
  
  ACTIVITY: Develop a sampling plan and data collection tools to be used for your project (60 min)
Testing, Refining and Implementing Measurement
Data Consistency and Stability

ACTIVITY: Develop a measurement plan (35 min)
Process Performance and Capability Measures
- Defect Measures
  - Yield, Rolled Throughput Yield, Defects per unit, Defects per million opportunities
    
    ACTIVITY: Calculate, RTY and DPMO (25 min)
- Process capability
- Process dashboards and balanced scorecards

Analyze

Process Analysis
- Value/Non-value added analysis
- Workflow principles and cycle time
  
  ACTIVITY: Complete a value and cycle time analysis (45 min)
Data Analysis

ACTIVITY: Practice exercise related to variation (5 min)
- Pareto charts
- Variation factors
- Histograms
- Run charts
- Box plots
  
  ACTIVITY: Create Pareto and Run Charts (35 min)
Considering Process Design/Redesign
- Key differences
- Benefits and challenges
- Managing design/redesign
Develop Root Cause Hypothesis
- Developing hypotheses
- Cause and effect
- Comparative analysis and logical cause testing
  
  ACTIVITY: Work on root cause analysis for your project, formulate hypothesis, construct cause and effect diagram (45 min)
Investigate and Verify Root Cause
- Scatter diagrams
  
  ACTIVITY: Interpret scatter plots and determine correlation (10 min)
- Correlation coefficients
- Logical cause testing
- Chi-square test
- Cause verification
  
  ACTIVITY: Chi-square calculation (25 min)
- Confidence testing

Improve

Generating Solution Ideas
- Creating innovative ideas
- Planning for brainstorming sessions
- Brainstorming and advanced idea generation techniques
  
  ACTIVITY: Practice using advanced idea generation techniques to develop a list of potential solutions (20 min)
Narrowing Ideas and Developing Proposed Solutions
- Tools for solution filtering
- "Should Be" process mapping
Selecting the Best Solution
- Cost Benefit Analysis
- Criteria matrix (review)
  
  ACTIVITY: Mini-Case Study using criteria matrix (30 min)
- Planning and Testing the Improvement Solution
- Planning and project management
- Piloting
  
  ACTIVITY: Prepare a piloting strategy based on case study (30 min)
- Unintended consequences
- Risk management
- FMEA (Failure Modes and Effects Analysis)
  
  ACTIVITY: Practice using FMEA on proposed solution (30 min)
- Mistake proofing
Evaluating, Refining and Expanding Solutions
- Implementation planning

Control

Control Plan
Planning Ongoing Measurement
- Monitoring SIPOC
- Dashboard review
- Ongoing Measurement Tools
- Control Charts
- Use and interpretation
- Construction methods
  
  ACTIVITY: Create a control based on predetermined data (15 min)
Developing Documentation

ACTIVITY: Understanding the importance of documentation (25 min)
- Documentation Hints
Preparing Revision and Response Plans

ACTIVITY: Draft a sample control plan (7 min)
Expanding the Gains & Concluding the Project
- Institutionalization
- Translating opportunities
- Storyboards
- Continuous improvement

Review and Conclusion