Course Outline

Define Phase

• The Basics of Six Sigma
  • Meanings of Six Sigma
  • General History of Six Sigma & Continuous Improvement
  • Deliverables of a Lean Six Sigma Project
  • The Problem Solving Strategy Y = f(x)
  • Voice of the Customer, Business and Employee
  • Six Sigma Roles & Responsibilities

• The Fundamentals of Six Sigma
  • Defining a Process
  • Serious Quality Characteristics (CTQ’s)
  • Poor Quality Cost
  • The Pareto Analysis (80:20 rule)
  • Six Sigma - Measurement Standards

• Selecting Lean Six Sigma Projects
  • Building a Business Case & Project Charter
  • Developing Project Metrics
  • Financial Evaluation & Benefits Capture

• Undestanding The Lean Enterprise
  • Lean – An Understanding and its History
  • The Combination of Lean & Six Sigma
  • The Seven Waste Elements
  • 5S
    • Straighten, Shine, Standardize, Self-Discipline, Sort

Measure Phase

• Process Definition
  • Cause & Effect / Fishbone Diagrams
  • Process Mapping, SIPOC, Value Stream Map
  • X-Y Diagram
  • Failure Modes & Effects Analysis (FMEA)

• Six Sigma Statistics
  • Basic Statistics
  • Descriptive Statistics
  • Normal Distributions & Normality
  • Graphical Analysis

• Measurement System Analysis
  • Precision & Accuracy
  • Bias, Linearity & Stability
  • Gage Repeatability & Reproducibility
  • Variable & Attribute MSA

• Process Capability
  • Capability Analysis
  • Concept of Stability
  • Attribute & Discrete Capability
  • Monitoring Techniques

Analyze Phase

• Patterns of Variation
  • Multi-Vari Analysis
  • Classes of Distributions

• Inferential Statistics
  • Understanding Inference
  • Sampling Techniques & Uses
  • Central Limit Theorem

• Hypothesis Testing
  • General Concepts & Goals of Hypothesis Testing
  • Significance; Practical vs. Statistical
  • Risk; Alpha & Beta
  • Types of Hypothesis Test

• Hypothesis Testing with Normal Data
  • 1 & 2 sample t-tests
  • 1 sample variance
  • One Way ANOVA

• Hypothesis Testing with Non-Normal Data
  • Mann-Whitney
  • Kruskal-Wallis
  • Mood’s Median
  • Friedman
  • 1 Sample Sign
  • 1 Sample Wilcoxon
  • One and Two Sample Proportion
  • Chi-Squared (Contingency Tables)

Improve Phase

• Simple Linear Regression
  • Correlation
  • Regression Equations
  • Residuals Analysis

• Multiple Regression Analysis
  • Non- Linear Regression
  • Multiple Linear Regression
  • Confidence & Prediction Intervals
  • Residuals Analysis
  • Data Transformation, Box Cox

• Designed Experiments
  • Experiment Objectives
  • Experimental Methods
  • Experiment Design Considerations

• Full Factorial Experiments
  • 2k Full Factorial Designs
  • Linear & Quadratic Mathematical Models
  • Balanced & Orthogonal Designs
  • Fit, Diagnose Model and Center Points

• Fractional Factorial Experiments
  • Designs
  • Confounding Effects
  • Experimental Resolution

Control Phase

• Lean Controls
  • Control Methods for 5S
  • Kanban
  • Poka-Yoke (Mistake Proofing)

• Statistical Process Control (SPC)
  • Data Collection for SPC
  • I-MR Chart
  • Xbar-R Chart
  • U Chart
  • P Chart
  • NP Chart
  • Xbar-S Chart
  • CumSum Chart
  • EWMA Chart
  • Control Methods
  • Control Chart Anatomy
  • Subgroups, Impact of Variation, Frequency of Sampling
  • Center Line & Control Limit Calculations

• Six Sigma Control Plans
  • Cost Benefit Analysis
  • Elements of the Control Plan
  • Elements of the Response Plan