Detailed Lean Six Sigma Content


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Detailed Lean Six Sigma Content

  1. 1. Detailed Black Belt Lean Six Sigma Course Content -Topics, Tools, and Methods- The Lean Six Sigma Program is a partnership between The University of Texas at Arlington and George Group. All training materials used in the course were developed by George Group. Two instructors are used, alternating from module to module of the course material. We feel that this approach provides the students with differing perspectives, and also helps to keep the instructors fresh. Lean Six Sigma is one of the most robust and extensive Six Sigma programs available in the country. The University of Texas at Arlington evaluated many of the leading providers in the country. We believe the content, software and integration of Lean and Six Sigma make this the most unique and most useful training available today. Lean and Six Sigma combined are the most powerful combination of improvement strategies and tools available to any business today. Training materials include three textbooks, four course notebooks, miscellaneous handouts, and Virtual Coach™ software. Virtual Coach™ software puts all the course materials into a handy reference and training tool, so slides, notes and topics can be quickly accessed for reference. Slides can be easily exported to MS Powerpoint™ for use in presentations and to train others on lean and six sigma concepts. Course participants have reading and homework assignments prior to each week of training. In addition, students are given assignments to familiarize themselves with Minitab statistical software. The textbooks used are as follows: • The Six Sigma Handbook by Pyzdek • Lean Six Sigma by George • What is Lean Six Sigma? by George & Kastle • Lean Six Sigma Pocket Toolbook by George, Maxey, et al Training is application based with simulations, exercises and Minitab™ lessons included throughout. Use of Minitab™ and computer spreadsheets are emphasized to support the lean and statistical calculations. Participants focus less on theory but more on how and when to use the tools effectively. Training is constantly practiced, reinforced and tested to ensure learning. Teachbacks, passing four exams (including a final comprehensive exam), and project presentations are required to complete the course certificate. Exercises are used throughout the course, with approximately a 60/40 split between manufacturing and transactional examples. The course material does include examples from both manufacturing and transactional processes for many modules, as appropriate. Content details are shown on the following pages. ________________________________________________________________________ George Group -1- UT-Arlington
  2. 2. Detailed Black Belt Lean Six Sigma Course Content -Topics, Tools, and Methods- • When to use and when not to use Lean Six Sigma • Introduction to Six Sigma and Lean- history and key concepts • Similarities and differences between Lean and Six Sigma and why their combined methodologies today are the most powerful vehicle for organization improvement • DMAIC Philosophy and Value-Based Selection • Team Launches and Communication • Basic Project Selection, Planning and Management o Project sponsor basics o Project selection and definition criteria o Project planning, management, tollgate reviews • Introduction to Variation and Basic Statistics: o Variation, Common Cause, Special Cause, Descriptive Statistics, Specifications, Process Tampering, Min, Max, Median, Mean, Standard Deviation, normal distributions, z-distributions, samples vs. populations, accuracy, precision, process stability and capability, reacting to data, Histograms, Boxplots, Dotplots, Main Effects Plot • Value of Cycle Time o Definitions and barriers for manufacturing and service o Capacity, Throughput, Manufacturing Cycle Time, Process Cycle Time, Process Cycle Efficiency, Process Sizing, bottlenecks o Little’s Law o Transactional Processes and cycle time • Voice of the Customer (VOC) o Customer wants, communication o Selecting, measuring and using key customer indicators and how o Converting Voice of customer to customer critical requirements and critical to quality requirements and outputs o Kano Analysis o Identifying bias in questioning/surveying customers o Customer sampling, surveying and interviewing guidelines • Lean Six Sigma and Supply Chain Metrics o Balanced scorecard, dashboards, linked dashboards o Examples and descriptions of key metric definitions within the supply chain o Information Flow • Learning the Supply Chain-Questions to Ask • Hidden Factory and Rolled Throughput Yield • Process Mapping o SIPOC Chart, high level vs. low level maps, general process mapping steps, Process and Product Matrix (Product Family Matrix), Top-Down Maps, Swim Lane Maps, Spaghetti Charts, Value-Stream Mapping, value-added vs. non- value added identification, collecting map data, different process map examples • Basic Tools o Brainstorming, Cause and Effect Diagram, Nominal Group Technique, Affinity Diagram, Force Field Analysis, Pareto Chart, Check Sheet ________________________________________________________________________ George Group -2- UT-Arlington
  3. 3. Detailed Black Belt Lean Six Sigma Course Content -Topics, Tools, and Methods- • Control Charts o Control Chart Decision Tree o Control limit calculations and interpretations; detecting lack of control o I-MR Chart; X-Bar and R chart, X-Bar and S chart o Normality test o Subgroup selection and sizing o Attribute Data and P-Chart o Autocorrelation • Central Limit Theorem • Process Capability o Cp, Cpk, Pp, Pp calculations and interpretations o Capability target values and action plans • Measurement System Analysis o Effects of measurement error and variation o Definitions of stability, linearity, bias, repeatability, reproducibility, discrimination o Doing and interpreting Gage R&R studies • Process Constraint Identification, Supply Chain Accelerator, and Load Factor Analysis • Takt Rate Analysis • Confidence Intervals for mean and standard deviations • Hypothesis Tests o 1 Sample t Test, 2-Sample t Test, 1-sided and 2-sided hypothesis tests, Paired t Tests • Errors and Risk o Type I and Type II Errors o Alpha, Beta, Producer, Consumer Risk o Power • Components of Variation and Sampling Strategies o Nesting Hierarchy o Components of variation o Sampling consideration o Considerations with ANOVA and Multi-vari Charts • Cause-and-Effect Matrix • Failure Mode Effect Analysis • Simple and Multiple Regression • One and Two Way Analysis of Variance (ANOVA) • MRP Review • Generic Pull Systems and WIP Caps o Includes analytical calculations of WIP caps o Coefficient of Variation and selection of WIP Control Parameters ________________________________________________________________________ George Group -3- UT-Arlington
  4. 4. Detailed Black Belt Lean Six Sigma Course Content -Topics, Tools, and Methods- • Replenishment Pull Systems: Manufactured and Purchased Parts o Defining and determining Manufacturing Cycle Time, Cycle Time Interval, safety stock, trigger points, order quantities, supplier lead times, order frequency, demand variability o Visual card, electronic, Synchronous Pull Systems o Implementation Process • 1-Bin and 2-Bin/Asynchronous Replenishment Pull • Part Stratification • Full and Fractional Design of Experiments and Analysis (Response surface methodology, EVOP, central composite, box benkin, mixtures are not discussed in detail • Kaizen Methodology • Analytical Batch Sizing • 5S • Setup Reduction • Line Balance Model and Approaches • TPM • Process Flow Improvement/Plant Layout Improvement • Stocking Strategy • Sales and Operations Planning • Defect Prevention o Inspection versus prevention o Poke-a-yoke (mistake proofing) • Visual Process Control Tools o Takt Boards, Production Boards, Issue Boards, 5S Boards, others • Process Control and Implementation Plans (to hold the gains on any Six Sigma project) • Process Commissioning (transfer of improvement leadership and maintenance to process owner) ________________________________________________________________________ George Group -4- UT-Arlington