· LSSGB Introduction - DMAIC Steps

· What is Six Sigma?

· Why 99% is not Good enough?

· 6 Sigma Synergy

· COPQ (Cost of Poor Quality) and 6 Sigma relation

· Six Sigma Benefits

· DMAIC Process

· Understanding DPU, PPM, DPMO with case study

· DMAIC VS DMADV VS DFSS (Understanding the difference)

· Difference between Lean Vs Six Sigma Methodology

Define Phase

· Introduction of Lean Six Sigma Green Belt (LSSGB)

· What is scoping and Why project scoping

· Scoping Technique - Longitudinal Scoping and Lateral Scoping

· Project Teams, Teaming Roles and Why Teaming?

· Project Benefit & Loss-Opportunity Grid

· 5W and 1H Technique -Define Problem Perfectly

· First Pass Yield (FPY) VS Rolled Throughput Yield

· TAKT Time VS Cycle Time VS Lead Time VS Throughput Time

Project Charter

· Understand Project Charter with Case Study

Measure Phase

· Why do we need a Process Map?

· Map the as is Process - What is Process? and SIPOC

· Define a Unit- What is a Unit? and define with examples

· What is Specification

· Types of Data - Understand the data characteristics- Types of Data and Continuous data characteristics

· Dispersion and Central Tendency- Measuring the of location, Spread and Shape

· Understanding Opportunities for Error (OFE)

· Design Sampling Plan for Establishing Process Baseline, Population and Sample

· Types of Sampling- Random Sampling and How big a sample?

· Validate Measurement System for 'Y' - Introduction of Measure, Perform GRR Study and types of measurement errors

· Accuracy and Precision

· R and R- Gage Reproducibility and Gage Repeatability

· Data Collection, Analyze Results - Continuous Data

· Toll Gate Criteria

· What is Benchmarking, Process and Steps

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

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

· Sources of Variation

· 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

MSA Minitab case study

· Attribute Agreement Analysis (Minitab Exercise)

· Variable Crossed Gauge RR (Minitab Case Study)

Basic Statistics

· Introduction to Basic Statistics- What is statistics? and Definition of Statistics

· Sample VS Population statistics

· Basic Statistics- Why do we use Statistics? What is Sample, Population and Sample

· Types of Data-Variable Vs Attribute data and Variable process outputs

Analyze Phase

· Establish Process Baseline - Six sigma metrics

· Define Performance Goals, Perform Entitlement and Benchmarking Exercise

· Concept of Z value

· Process Entitlement

· Process Capability Study and Limitations of Process Capability

· Analyzing Continuous Data- Histogram

· Stratification, Using Minitab for Stratifying Data and 5 minutes exercise

· Sigma Multiple Case Study

· Benchmarking and Steps

· t distribution- Introduction and Using the t-distribution Table

· Estimate Population Parameter from Sample Statistic, point estimate and Interval estimates using t-distribution

· Hypothesis Testing- Null Hypothesis and Alternative Hypothesis

· Type1 and 2 Error

· Forming Hypothesis- Two-tailed and one-tailed Tests of Hypothesis and Acceptance/Rejection criteria for hypothesis

· Identify variation source, Generating and Prioritizing X's

· Brainstorming and Multivoting

· Process Mapping

· Explain Fishbone with example

· Prioritization Tool, Pareto Diagram

· Correlation - Association between Variables and Correlation levels

· Linear Regression and (SLR) Simple Linear Regression

· Multiple Linear Regression (MLR)

· Failure Mode and Effect Analysis (FMEA)- Concept and Output, FMEA Table and Scales of 'SOD'

Problem-Solving Tools & concepts

· Fishbone Diagram or Cause-Effect Diagram

· Fishbone Diagram 'Case Study'

· Pareto Chart or Pareto Diagram- A Prioritization Tool

· Pareto Chart

· Flow Chart Method

· Histogram -Data Distribution Tool

· Check Sheet

· Scatter Plot or Scatter Diagram

· Control Chart and its types

· 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

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

· How to Select Proper Graph for analysis

· Sampling and types of sampling

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

· Understanding Cause and Effect Matrix with a case study

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 Crossed VS Nested Design

· ANOVA (Minitab Case Study)

Regression Analysis

· Regression- Introduction to Linear Regression

· Scatter Diagram, Regression (Minitab Example)

· ANOVA for Linear Regression and Normality of Residuals

· Regression- Interpolation and Extrapolation

· Scatter, Correlation and Regression (Minitab Exercises)

Improve Phase

· Intro to Improve & DOE- Explore Potential Causes

· DOE Nomenclature

· Factorial Design, Types of Experiment Designs (Factorial Designs, Various factor and Level Designs)

· DOE setting- Two Level and Three Factor Design

· Optimizing y and X- Design, Define and Determining Operating Limits

· Counter-Measure Matrix

· Should Be Process Map, Resistance Analysis

Control Phase

· Intro and Controlling the X

· Correction Loop

· Mistake Proofing (Poka-Yoke), Mistake Proofing Techniques and Advantages of Mistake – Proofing

· Selecting Control Chart and Action Plan for Out of Control of X's

· Problem Solving Flow, Project closure and Tollgate Control

· 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

Lean Tools

· What is Kaizen? What is MUDA and Types of MUDA

· 7 Types of MUDA or Waste

· Single Minute Exchange of Dies (SMED)

Employee Motivation and Relevant Theory

· Motivational Technique and Fredrick Taylor Concept

· Hawthorne Study

· Maslow's Law of Hierarchy

Lean Six Sigma Real World 05 Case Studies

Multiple Practice / Sample MCQ Test Papers

Additional Resources