Session 1:
Introduction To Lean Six Sigma

•

Introduction

•

Higher Standards for Higher Performance

•

Input Determines Output

•

Lean Six Sigma Defined

•

What's In a Name?

•

The 5 Lean Principles

•

The 8 Forms of Waste

•

Success Stories

•

The Sigma Level

•

The 99.9% Problem

•

Introduction to EngineRoom^{®}

•

DNA of a Champion

•

Lean Six Sigma Framework

•

DMAIC  The Improvement Process

•

Lean and DMAIC

•

Thought Process Mapping  Toolset

•

Organizing for Success

•

Working Relationships

•

Critical Success Factors

•

Skill Check

Session 2:
Define I  Starting A Project and Leading Teams

•

Getting Started  Project Initiation

•

Balanced Scorecard Toolset

•

Project Selection Toolset

•

Project Charter Toolset

•

Project Planning & Tracking Toolset

•

Leadership Thinking

•

Robot Leadership

•

Fueling The Improvement Engine

•

Leadership Characteristics

•

Practice, Study and Reflection  Learning by Modeling

•

Leading Teams

•

Developing an Effective Team

•

Improving Team Development

•

4 Conversations Toolset

•

Leading Change

•

Leading Change  Continued

•

Success Factors For Effective Change Management

•

Stakeholder Analysis  RACI Matrix

•

Leadership Reflection

•

Exercises and Quiz

Session 3:
Define II  Voice of the Customer

•

Voice of The Customer

•

Focus on The Customer

•

Understanding Customer Requirements

•

Where to Go For Customer Requirements

•

Conducting Surveys

•

Survey Considerations

•

Surveys  Sampling Frame

•

Structuring Survey Questions

•

The Degree of Uncertainty in Sampling

•

Guideline for Margin of Error

•

Affinity Diagram Toolset

•

CTQC Tree Diagram Toolset

•

Operational Definition Toolset

•

Voice Of The Customer As Specifications

•

QFD Toolset

•

Exercises and Quiz

Session 4:
Define III  Mapping the Process

•

Drawing a Process Picture

•

Process Thinking

•

The Source of Value

•

The Source of Value: Gemba

•

Process Mapping  Overview

•

Process Mapping (SIPOC) Toolset

•

Flow Charts

•

ValueAdded Flow Charts

•

Spaghetti Charts

•

Takt Time

•

Value Stream Mapping Toolset

•

Define Tollgate  Progress Review

•

Exercises and Quiz

Session 5:
Measure I  Measurements and Basic Statistics

•

Measurements and Basic Statistics

•

Business Problem Solving

•

Basic Statistical Terms

•

Descriptive and Inferential Statistics

•

Measurements

•

Discrete vs. Continuous Measurements

•

Measurement Subjects

•

Graphical Summaries

•

Pareto Chart Toolset

•

Histogram Toolset

•

Understanding Variation

•

Measuring Central Tendency

•

Quantifying Process Variability

•

The Normal Distribution

•

Exercises and Quiz

Session 6:
Measure II  Measurement System Analysis

•

Measurement System Analysis  Introduction

•

Measurement as a Process

•

Cause & Effect Matrix Toolset

•

The Analysis of Measurement Systems

•

The Requirements of Measurement Systems

•

Variable MSA  Gauge R & R

•

MSA  Graphing

•

Attribute Measurement System Analysis

•

Calibration of Measurement Systems

•

Collecting Data

•

Developing a Sampling Plan

•

Baseline Performance

•

Derivative Performance Metrics  Throughput Yield

•

Derivative Performance Metrics  Rolled Throughput Yield

•

Calculating the Sigma Level  Toolset

•

Exercises and Quiz

Session 7:
Measure III  Charting Process Behavior

•

Introduction  Charting Process Behavior

•

Trend Chart Toolset

•

SPC  Introduction and Background

•

SPC  Introduction to Control Charts

•

SPC  Control Chart Limits

•

SPC  More On Control Limits

•

Implementing SPC

•

SPC Chart Selection

•

Rational Subgrouping Toolset

•

X and Moving Range Charts  Toolset

•

Attribute Control Chart Toolset

•

Xbar and R Chart Toolset

•

Process Capability Toolset

•

The Sigma Level Revisited

•

Measure Tollgate  Progress Review

•

Exercises and Quiz

Session 8:
Analyze I  Identifying Potential Root Causes

•

ANALYZE I  Introduction

•

Finding The Root Cause

•

Cause & Effect Diagram Toolset

•

Alternative To The Cause & Effect Diagram

•

5Why, 1How

•

A Combination of 5Why, Pareto, and Trend Charts

•

Box Plots Toolset

•

Scatter Plot Toolset

•

Correlation and Regression Analysis

•

Multiple Regression Toolset

•

Binary Logistic Regression Toolset

•

Factors In Determining Sample Size

•

Estimating Population Mean

•

Exercises and Quiz

Session 9:
Analyze II  Hypothesis Testing

•

ANALYZE II  Introduction

•

Introduction to Hypothesis Testing

•

The Process On Trial

•

The Hypothesis  Accept or Reject?

•

Types of Error

•

Power Analysis

•

Power Analysis  Factors

•

Hypothesis Testing

•

Confidence Intervals

•

Treatment Comparisons  Control Charts

•

Comparing One Proportion to a Standard

•

Comparing Two Proportions Toolset

•

Comparing Multiple Proportions  ChiSquare

•

Comparing One Mean to a Standard  ttest

•

Comparing Two Means  ttest Toolset

•

Comparing Multiple Means  ANOVA /Ftest Toolset

•

Comparing One Variance to a Std.  ChiSquare

•

Comparing Two Variances  Ftest Toolset

•

Parametric vs. Non Parametric Tests

•

Non Parametric Toolset

•

Hypothesis Testing Learning Lab

•

Exercises and Quiz

Session 10:
Analyze III  Design of Experiments

•

Design of Experiments  Introduction

•

Design of Experiments  History

•

Design of Experiments  Components

•

Design of Experiments  Principles

•

Design of Experiments  Purpose

•

Design of Experiments  Process

•

Design of Experiments  Guidelines

•

Selecting the Right Design

•

Blocking

•

Blocking and Tackling

•

Faster Deliveries Through Experimentation

•

Beyond OneFactor Experiments

•

Two Level Full Factorial Toolset

•

Two Level Fractional Factorial Toolset

•

General Factorial Toolset

•

DOE Power and Sample Size

•

Designing An Experiment To Save The Kingdom

•

Better Pizza Through Design of Experiments

•

Designing Experiments to Sell More Coffee

•

Additional Subjects

•

Analyze Tollgate  Progress Review

•

Design of Experiments Exercises and Quiz

Session 11:
Improve

•

Improve

•

Design for Lean Six Sigma (DFSS)

•

Benchmarking

•

Brainstorming

•

Narrowing Down The List of Ideas

•

FMEA Toolset

•

Errorproofing

•

Prioritizing and Selecting a Solution

•

The A3 OnePage Report

•

Continuous Flow Toolset

•

Quick Changeover Toolset

•

Cellular Processing Toolset

•

Leveling Production (Heijunka)

•

The Theory of Constraints (TOC) Toolset

•

Pull System Overview

•

Pull Scheduling

•

Core Process Pull Toolset

•

Replenishment Pull Overview

•

Kaizen Toolset

•

Corrective Action Matrix

•

Piloting a Solution

•

System Dynamics Toolset

•

Improve Tollgate  Progress Review

•

Exercises and Quiz

Session 12:
Control

•

Control

•

Control Charts Revisited

•

The Process Control Plan

•

More On FMEA

•

Visual Management

•

5S Approach

•

CHECK Process

•

Total Productive Maintenance

•

TPM Objectives & Benefits

•

TPM Metrics

•

TPM Core Elements

•

TPM Maintenance Activities

•

Best Practices and Lessons Learned

•

Standardized Work  Documenting Process Changes

•

Ending the Project

•

Control Tollgate  Progress Review

•

Exercises and Quiz

•

Course Completion

•

The Lean Six Sigma Journey
