· What is Six Sigma?

· Why Six Sigma is not good enough?

· Variance Based Thinking and ISO VS TQM VS Six Sigma

· Cost of Quality and Six Sigma relationship, Benefits of Six Sigma

· DMAIC Stages overview

· DMAIC Stages VS tools, DMAIC VS DMADV

· Understanding DPU, PPM, DPMO with case study

· Difference between Lean Vs Six Sigma Methodology

· TAKT Time VS Cycle Time VS Lead Time VS Throughput Time – Difference explained with example

LSSBB Define Phase

· Establish Critical to Quality (CTQ) Characteristics

· Explore Customer CTQ and Examples of Customer Responses on CTQs

· Kano Diagram and Implied Needs, Stated Needs, Unstated Needs and Shifting Needs

· Define Internal CTQ and CBP

· Quality Function Deployment (QFD) and Typical 4 House QFD

· QFD Flow in Various Environments, Benefits and Examples of QFD

· Define a Project and Project Approach to Six Sigma

· Types of Project Selection and Steps in Project Selection

· Brainstorming and Multivoting

· Theme selection Matrix and Define Ways to Select a Project

· Project Selection Summary

· Scope the Project

· SIPOC method

· Developing Team Charter. Reason for Teaming and Team Composition

· Quantify Benefits and Project Sign off

· Defining Problem Statement and Kick off the Project

· Create Matrix with Team and Define Tollgate

· First Pass Yield (FPY) VS Rolled Throughput Yield

· 5W and 1H Technique -Define Problem Perfectly

· SMART Goal Setting

· Cost of Quality (COQ), Its Categories and benefits

· Understanding Project Charter with Case Studies

LSSBB Measure Phase

· Introduction to Measure

· Establish Performance Parameters Process and SIPOC Diagram

· Process Mapping Nomenclature and Benefits of Process Mapping

· Define a Unit and Define Specifications Defect

· What is Specification and What is a Characteristic?

· Develop Operational Definition with Examples

· Understand Data Characteristics and Why collect data?

· Types of data and data characteristics

· Which type of data is Preferable and Design Sampling Plan for Establishing Process Baseline

· Introduction to Sampling and Types of Sampling

· Validate Measurement System for 'Y' and Types of Measurement Errors

· Sources of Variation and Accuracy and Precision

Measurement System Analysis (MSA)

· Introduction to Measurement System Analysis (MSA)

· Understand Measurement as a Process

· Sources of Variation

· Fundamental Properties of Measurement System

· Accuracy and Precision

· Location and Spread error

· Bias, Linearity and Stability

· Possible Causes for Bias, Linearity

· Repeatability and Reproducibility

· Measurement Capability Index

· How to Conduct Variable Gauge R and R

· Acceptance Criteria (variable Gauge MSA)

· Variable Gauge R and R Study in Excel (Case Study)

· Attribute Agreement Analysis and Acceptance Criteria

· Attribute Agreement Analysis (Minitab Case Study)

· Variable Crossed Gauge RR (Minitab Case Study)

LSSBB Analyze Phase

· Establish Process Baseline and Defects per Million Opportunities (DPMO)

· Categorizing Defects - Pareto Diagram and Z Calculation Worksheet - Discrete Data

· Introduction to Normal Distribution and Standard Normal Distribution

· Concept of Z Value

· Process Sigma Multiple for Continuous Data and Concept of Process shift

· Variation Names of Process Variations and Calculating Process variations

· Process Capability Study and Capability Index

· Analyzing Continuous Data- Histograms

· Analyzing Continuous Data- Run Charts

· Stratification and Using Minitab for Stratifying Data

· Analyzing Patterns in Process Distribution and Transformation

· Sampling Distribution and Graphical Representation

· Introduction to t-distribution and Use of t-distribution Table

· Estimate Population Parameter from Sample Statistic and Interval Estimates using t-distribution

· Define Performance Goals and Entitlement on Cycle Time

· Process of Benchmarking

· Introduction to Hypothesis Test, Null and Alternate Hypothesis

· Type 1 and Type II Error

· Test Criteria of the Hypothesis- Two Tailed & One Tailed Test of Hypothesis

· Improvement Goal on Discrete Data and Binomial Distribution

· Introduction to Poisson Distribution

· Chi Square Test and Preparing Contingency Table

· Improvement Goal on Continuous Data and One Sample Two-sided t-Test

· ANOVA-One Way and Two Way

· F-Test -Hypothesis Test with Minitab

· Identify Variation Sources

· Fishbone- Mile Deep & Not Wide and Fishbone Structure

· Prioritization Tool

· Prioritization Tool- Pareto Chart

· What is Correlation Analysis?

· What is Regression & Simple Linear Regression? How to do in Minitab

· Multiple Linear Regression (MLR) and Polynomial Regression

· Analysis of Variance (ANOVA)

· Analysis of Means (ANOM)

· General Linear Model of ANOVA

· Chi-Square Test with Minitab

· Failure Mode and Effects Analysis

· Theory of Constraints (TOC)

Basic Problem-Solving Tools

· Fishbone Diagram or Cause-Effect Diagram

· Fishbone Diagram 'Case Study

· Pareto Chart or Pareto Diagram- A Prioritization Tool

· Pareto Chart (Case Study)

· Flow Chart Method

· Histogram -Data Distribution Tool

· Check Sheet (with case study)

· Scatter Plot or Scatter Diagram

· Control Chart and its types

Cause and Effect Matrix- Prioritization Tool

· Cause and Effect Matrix

· Cause and Effect (Case Study)

Support Problem-Solving Tools and modules

· Box and Whisker Plot

· RACI Matrix Chart- Introduction, Key Responsibility Roles (RACI Model), PARIS, PACSI, RASCI, DACI, and CAIRO

· What is Threat and Opportunity Matrix? Why Opportunity and Threat Matrix and Case Study

· Critical to Quality Tree (CTQ Tree), Case Study- Meal Performance and Customer Requirement

· SIPOC Diagram - Introduction, how can SIPOC be used? How SIPOC works and SIPOC Diagram Type 2

· Types of Six Sigma Certifications and their Roles - Different Levels of sigma and Roles

· How to Select Prepare Graph for analysis in Minitab

· Sampling and types of sampling

· Overview for Multi-Vari Chart(Minitab), Multivari Analysis and Case Study of Multi Vari Chart

Analysis of Variance (ANOVA)

· Intro to ANOVA (Analysis of Variance)

· ANOVA-Additivity and Total Variance- Data Dimension and Total Variance Calculation

· ANOVA (One Way ANOVA Step 1 and 2)- Components of Variation and Calculation of the sum of squares

· ANOVA (Degree of Freedom)

· ANOVA- Calculation of Mean Square, Calculation of the F- Ratio and Testing for significance

· ANOVA in Minitab- 95% Confidence Intervals

· ANOVA Summary and Crossed VS Nested Design

· ANOVA (Minitab Case Study)- Molding Process

Analysis of Means (ANOM)

· Introduction to ANOM

· Difference between ANOVA and ANOM

· Minitab Case Study

Regression Analysis

· Intro to Regression and Scatter Plot

· Correlation Analysis

· Introduction to Linear Regression

· Scatter Diagram, Regression (Minitab Example)

· ANOVA for Linear Regression and Normality of Residuals

· Regression- Interpolation and Extrapolation summary

· Scatter, Correlation and Regression (Minitab Exercises)

Non-Parametric Test

· Introduction to Non- Parametric Test. Difference between Parametric and Non-Parametric Test

· Sample Sign Test

· Man Whitney Test

· Moods Median Test

· Kruskal Wallis Test

LSSBB Improve Phase

· Explore Potential Causes and Deign of Experiments (DOE)

· DOE Nomenclature

· Types of Experiment Designs and Factorial Designs

· DOE setting in Designs- Two level & Three Factor Design

· Establish Variable Relationships and Determine the Operating Limits

· Counter-Measure Matrix

· Map the new Process and Sources of Resistance

· Introduction, Benefits, and How DOE works?

· How DOE works –Example

· DOE Key Terms

· Steps, One Factor at a Time (OFAT), Trial and Error, Fractional Factorial

· Creating a design in Minitab

LSSBB Control Phase

· Verify Process Improvement- Correction Loop

· Statistical Process Control

· SPC Condition for Out-of-Control Situations

· Choosing an Appropriate Control Chart

· Control Phase- Continuous Data and Discrete Data

· I & MR Control Chart and X bar & R Control Chart

Process Capability Study

· Intro to Process Capability Study

· What is Capability?

· VOC and VOP

· Quality Improvement Model

· Capability Indices, Cp and Cpk

· Graphical Representation of Cp and Cpk

· Process Capability Index Cpk

· Capability for One Spec Limit

· Long Term Capability Study (Pp and Ppk)

· Acceptance Criteria -Capability Study

· Machine Capability Study| Process Capability VS Machine Capability

Attribute Control Chart

· Introduction to Attribute Control Charts

· Introduction to 'p' Chart

· 'p'-Chart (Minitab Case Study)

· Introduction to 'np' Chart

· 'np'-Chart (Minitab Case Study)

· Introduction to 'u' Chart

· 'u'-Chart (Minitab Case Study)

· Introduction to 'c' Chart

· 'c'-Chart (Minitab Case Study)

· Where to use which attribute Charts?

· Formula for Discrete Control Charts

Important Lean Tools

· 5S -Work Place Management System

· KAIZEN, MUDA and its types

· Single Minute Exchange of Dies (SMED)

· Mistake Proofing Technique

· Value Stream Mapping (VSM)

Employee Motivation and Relevant Theory

· Motivational Technique and Fredrick Taylor Concept

· Hawthorne Study

· Maslow's Law of Hierarchy

· Mc Gregor Theory X and Theory Y

Lean Six Sigma Real World 08 Case Studies

Multiple Practice / Sample MCQ Test Papers

Additional Resources