Session 1:
Introduction to Lean Six Sigma

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Introduction

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Higher Standards for Higher Performance

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Input Determines Output

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Lean Six Sigma Defined

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What's In a Name?

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The 5 Lean Principles

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The 8 Forms of Waste

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Success Stories

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The Sigma Level

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The 99.9% Problem

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DNA of a Champion

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Lean Six Sigma Framework

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DMAIC  The Improvement Process

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Lean and DMAIC

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Thought Process Mapping  Toolset

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Organizing for Success

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Working Relationships

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Introduction to EngineRoom^{®}

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Skill Check

Session 2:
Define I  Starting a Project and Leading Teams

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Getting Started  Project Initiation

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Project Selection Toolset

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Project Charter Toolset

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Project Planning & Tracking Toolset

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Leadership Thinking

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Robot Leadership

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Fueling The Improvement Engine

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Leading Teams

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Developing an Effective Team

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Improving Team Development

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4 Conversations Toolset

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Leading Change

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Leading Change  Continued

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Success Factors For Effective Change Management

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Stakeholder Analysis  RACI Matrix

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Leadership Reflection

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Exercises and Quiz

Session 3:
Define II  Voice of the Customer

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Voice Of The Customer

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Focus on The Customer

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Understanding Customer Requirements

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Where to Go For Customer Requirements

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Conducting Surveys

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Survey Considerations

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Surveys  Sampling Frame

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Structuring Survey Questions

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The Degree of Uncertainty in Sampling

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Guideline for Margin of Error

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Affinity Diagram Toolset

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CTQC Tree Diagram Toolset

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Operational Definition Toolset

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Voice Of The Customer As Specifications

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Exercises and Quiz

Session 4:
Define III  Mapping the Process

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Drawing a Process Picture

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Process Thinking

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The Source of Value

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The Source of Value: Gemba

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Process Mapping  Overview

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Process Mapping (SIPOC) Toolset

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Flow Charts

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ValueAdded Flow Charts

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Spaghetti Charts

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Takt Time

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Value Stream Mapping Toolset

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Define Tollgate  Progress Review

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Exercises and Quiz

Session 5:
Measure I  Measurements and Basic Statistics

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Measurements and Basic Statistics

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Business Problem Solving

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Basic Statistical Terms

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Descriptive and Inferential Statistics

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Measurements

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Discrete vs. Continuous Measurements

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Measurement Subjects

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Graphical Summaries

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Pareto Chart Toolset

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Histogram Toolset

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Understanding Variation

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Measuring Central Tendency

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Quantifying Process Variability

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The Normal Distribution

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Exercises and Quiz

Session 6:
Measure II  Measurement System Analysis

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Measurement System Analysis  Introduction

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Measurement as a Process

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Cause & Effect Matrix Toolset

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The Analysis of Measurement Systems

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The Requirements of Measurement Systems

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Variable MSA  Gauge R & R

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MSA  Graphing

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Attribute Measurement System Analysis

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Calibration of Measurement Systems

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Collecting Data

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Developing a Sampling Plan

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Baseline Performance

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Derivative Performance Metrics  Throughput Yield

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Derivative Performance Metrics  Rolled Throughput Yield

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Calculating the Sigma Level  Toolset

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Exercises and Quiz

Session 7:
Measure III  Charting Process Behavior

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Introduction  Charting Process Behavior

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Trend Chart Toolset

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SPC  Introduction and Background

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SPC  Introduction to Control Charts

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SPC  Control Chart Limits

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SPC  More On Control Limits

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Implementing SPC

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SPC Chart Selection

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Rational Subgrouping Toolset

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X and Moving Range Charts  Toolset

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Attribute Control Chart Toolset

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Xbar and R Chart Toolset

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Process Capability Toolset

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Measure Tollgate  Progress Review

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Exercises and Quiz

Session 8:
Analyze I  Identifying Potential Root Causes

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ANALYZE I  Introduction

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Finding The Root Cause

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Cause & Effect Diagram Toolset

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5Why, 1How

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A Combination of 5Why, Pareto, and Trend Charts

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Scatter Plot Toolset

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Correlation and Regression Analysis

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Multiple Regression Toolset

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Factors In Determining Sample Size

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Estimating Population Mean

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Exercises and Quiz

Session 9:
Analyze II  Hypothesis Testing

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ANALYZE II  Introduction

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Introduction to Hypothesis Testing

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The Process On Trial

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The Hypothesis  Accept or Reject?

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Types of Error

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Hypothesis Testing

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Confidence Intervals

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Treatment Comparisons  Control Charts

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Comparing Two Proportions Toolset

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Comparing Two Means  tTest Toolset

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Comparing Multiple Means  ANOVA Toolset

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Hypothesis Testing Learning Lab

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Analyze Tollgate  Progress Review

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Exercises and Quiz

Session 10:
Improve

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Improve

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Design for Lean Six Sigma (DFSS)

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Benchmarking

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Brainstorming

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Narrowing Down The List of Ideas

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FMEA Toolset

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Errorproofing

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Prioritizing and Selecting a Solution

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The A3 OnePage Report

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Continuous Flow Toolset

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Leveling Production (Heijunka)

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Quick Changeover Toolset

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Cellular Processing Toolset

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Pull System Overview

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Pull Scheduling

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Core Process Pull Toolset

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Kaizen Toolset

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Corrective Action Matrix

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Piloting a Solution

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System Dynamics Toolset

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Improve Tollgate  Progress Review

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Exercises and Quiz

Session 11:
Control

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Control

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Control Charts Revisited

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The Process Control Plan

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More On FMEA

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Visual Management

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5S Approach

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Total Productive Maintenance

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TPM Objectives & Benefits

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TPM Metrics

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Best Practices and Lessons Learned

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Standardized Work  Documenting Process Changes

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Ending the Project

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Control Tollgate  Progress Review

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Exercises and Quiz

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Course Completion

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The Lean Six Sigma Journey
