Lean Six Sigma GB + BB(I)

DEFINE Phase:

Learning Objectives

• Key Deliverables

• Voice of the Customer

Customer Identification

• Identify Internal & External customers

• Project impact on stakeholders

Customer Data Collection

• Data Collection Methods

Customer Requirements

• Critical-to-X (CTX)

• Critical-to-Quality (CTQ) Tree

• Quality Function Deployment (QFD)

• KANO Model

Business Case & Project Charter

• Project Charter

  • Business Case

  • Problem Statement

  • Goals & Objectives

• Business Case & Project Charter

  • Project Charter (Continued from the previous slide)

    1. Project Performance Requirements

    2. Project Charter Review

• Project Management Tools

  • GANTT Chart

  • Toll-gate Review

• Analytical Tools

  • Affinity Diagram

  • Tree Diagram

MEASURE Phase:
 

• Data Collection

  • Sampling (Continued from the previous slide)

    • Methods of Sampling

    • Illustrations

• Measurement System Analysis

  • Continuous Measurements

    • Gage R&R (Crossed)

    • Gage R&R (Nested)

  • Applicability of Measurement Systems to different organizational functions

• Statistics

  • Central Limit Theorem

  • Probability

    • Terms & Concepts

• Statistics

  • Probability (Continued from the previous slide)

    1. Probability Distributions:-

       • Poisson Distribution

       • Binomial Distribution

• Process Capability Studies

  • Process Capability Indices

    • Basics

    • Cp and Cpk

    • Pp and Ppk

  • Process Capability for Attribute Data

    • Binomial Capability

    • Poisson Capability

ANALYZE Phase:
 

• Learning Objectives

• Key Deliverables

• Measuring & Modeling Relationships Between Variables

  • Correlation Coefficient

    • Background & Meaning

    • MINITAB Analysis

    • Interpretation

  • Linear Regression

    • Background & Meaning

    • Regression Equation

    • P-value, S, R², and adjusted R²

    • ANOVA Table

    • Predicted Values

    • Residuals

• Hypothesis Testing

  • Terminology (Definition & Interpretation)

  • Statistical Vs. Practical Significance

  • Power & Sample Size

    • 1-Sample Z & 1-Sample t

    • 1 Proportion & 2 Proportions

  • Test for Means, Variances, and Proportions

    • 2-Sample t & Paired t

    • 1-Sample Poisson Rate

  • Analysis of Variance (ANOVA)

    • One-Way

  • Goodness-of-Fit tests

    • Goodness-of-Fit for Poisson

• Hypothesis Testing (Continued…)

  • Contingency Tables

    • Chi-square and Tests of Contingency Tables

  • Nonparametric Tests

    • Kruskal-Wallis

    • Mann-Whitney

• Additional Analysis Methods

  • Gap Analysis

  • Root Cause Analysis (RCA)

    • Purpose of RCA

    • Fault-tree Analysis (FTA)

    • Corrective Action-Preventive Action (CAPA) mechanism

IMPROVE Phase

Learning Objectives

• Key Deliverables

• Design of Experiments

  • Terminology

  • Design Principles

  • Planning Experiments

• LEAN Methods

  • 5S

  • Poka-Yoke / Mistake-Proofing

  • KANBAN

  • Push-Pull System / Strategy

  • Standardized Work

  • JIDOKA

CONTROL Phase:

• Learning Objectives

• Key Deliverables

• Statistical Process Control (SPC)

  • Objectives of SPC

  • Selection of variables for Control Chart monitoring

  • The principle of Rational Sub-grouping

  • Control Chart Selection

    1. Decision-Making Tree

    2. Control Chart for Continuous Data:-

       1. X-bar & R-chart

       2. X-bar & S-chart

    3. Control Chart for Discrete Data

       1. c-Chart (Number of Incidents)

       2. p-chart (Percent defective)

       3. np-Chart (Number of Defectives)