Process Design Excellence Green Belt - EngineRoom

Course Map

Total Estimated Hours:  45.2

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
  • 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
  • Skill Check

SESSION 3: Concept: Divergent Thinking 2.55 HOURS

  • Introduction
  • Metrics
  • The Core Principle of DFSS
  • Benchmarking
  • Beyond Customer Requirements
  • Brainstorming
  • Encouraging The Creative Process
  • Narrowing Down The List of Ideas
  • Pugh Concept Selection Toolset
  • Progress Review - Concept Phase
  • Skill Check

SESSION 4: Analytics for Design I: Statistics and Process Capability 7.4 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
  • SPC - Introduction to Control Charts
  • SPC - Control Chart Limits
  • SPC - More On Control Limits
  • X and Moving Range Charts - Toolset
  • Process Capability Toolset
  • 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
  • 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
  • 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
  • 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
  • Standardized Work - Documenting Process Changes
  • Launch
  • Ending a Project
  • Progress Review - Verify Phase
  • Skill Check
  • Course Completion and Feedback
  • The Lean Six Sigma Journey