Process Design Excellence Green Belt - EngineRoom

Course Map

Total Estimated Hours: 45

SESSION 1: Introduction to Process Design Excellence 3.6 HOURS

Process Design Excellence
What is Design Excellence?
Design Thinking
Closing the Gap
Better Aim Through Design
Improving Lifecycle Cost
DCDOV - The Design Roadmap

DCDOV and DMAIC
Design Leverage
Design Excellence Achievements
Introduction to EngineRoom^®
Project Tracking Toolset
Project Charter Toolset
Session Wrap-Up and Skill Check

SESSION 2: Define: Understanding the Voice of the Customer 6.25 HOURS

Introduction
Obtaining the Voice of The Customer
Market Segmentation
Understanding Customer Requirements
Listening to All the Voices
Where to Go For Customer Requirements
Conducting Surveys
Survey Considerations
Surveys - Sampling Frame

Structuring Survey Questions
Affinity Diagram Toolset
CTQC Tree Diagram Toolset
Operational Definition Toolset
Voice Of The Customer As Specifications
QFD Simplified Toolset
Progress Review - Define Phase
Session Wrap-Up and Skill Check

SESSION 3: Concept: Divergent Thinking 2.85 HOURS

Introduction
Metrics
The Core Principle of DFSS
Benchmarking
Beyond Customer Requirements
Brainstorming

Structured Brainstorming
Process Design Principles
Narrowing Down The List of Ideas
Pugh Concept Selection Toolset
Progress Review - Concept Phase
Session Wrap-Up and Skill Check

SESSION 4: Analytics for Design I: Statistics and Process Capability 7.65 HOURS

Introduction - Charting Process Behavior
Business Problem Solving
Basic Statistical Terms
Descriptive and Inferential Statistics
Graphical Summaries
Understanding Variation
Measuring Central Tendency
Quantifying Process Variability

The Normal Distribution
Distribution Identification
SPC - Introduction to Control Charts
SPC - Control Chart Limits
SPC - More On Control Limits
X and Moving Range Charts - Toolset
Process Capability Toolset
Session Wrap-Up and Skill Check

SESSION 5: Analytics for Design II: Statistical Testing 9.15 HOURS

Statistical Testing
Introduction to Hypothesis Testing
The Process On Trial
The Hypothesis - Accept or Reject?
Types of Error

Hypothesis Testing
Comparing One Mean to a Standard - t-test
Comparing Two Means - t-test Toolset
Comparing Multiple Means - ANOVA Toolset
Session Wrap-Up and Skill Check

SESSION 6: Design: Converging on a Solution 3.4 HOURS

Introduction
Design Development
Results By Design
Design Scorecard
Analyzing Designs
Transfer Function Toolset

Error-proofing
FMEA Toolset
Product and Process Reliability
Basic Reliability Calculations
Progress Review - Design Phase
Session Wrap-Up and Skill Check

SESSION 7: Optimize: Fine-Tuning the Design Solution 9.4 HOURS

Introduction
Building a Process Model
From Process Diagram to Process Model
Optimization
Predicting Process Performance With Simulation
Introduction to Discrete Event Simulation - Process Playground
Case Study: The Beginning
Case Study: Running The Model
Case Study: Interpreting Results
Case Study: Expanding Product Line

Case Study: Adding Capacity
Case Study: Doubling Down
Case Study: Managing Inventory
Case Study: Creating Flow
Case Study: Controlling Work in Process
Monte Carlo Toolset
Continuous Flow Optimization Toolset
Design For Lean - Supply Chain Dynamics
Progress Review - Optimize Phase
Session Wrap-Up and Skill Check

SESSION 8: Verify: Validating New Design Performance 3.45 HOURS

Introduction
Other Aspects of Verification
The Process Control Plan
Testing a Design
Achieving Reliability Through Testing
Piloting a Design
Control Charts Revisited

Standard Work - Documenting Process Changes
Launch
Ending a Project
Progress Review - Verify Phase
Session Wrap-Up and Skill Check
Course Completion and Feedback
The Lean Six Sigma Journey