Lean Six Sigma Training Solutions

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Lean Six Sigma Training Solutions

  1. 1. About Us About LSMI – www.leansigma.asia About Dr.Jagadish Barik (Lean Sigma Management Institute) Dr Jagadish Barik has nearly twenty one years of The Dr. Jagadish Barik’s Lean Sigma experience in manufacturing & Service Industries Management Institute (LSMI) is focussed on in deployment of Lean, Six Sigma, Business high quality, customer responsive education Excellence models ( RBNQA,CII-EXIM, Deming) ,consultancy, research and advisory TQM ,TPM, 5S,BSC, BPMS, SPC, Kaizen, services to corporations & goverments. Visual Management, Quality Circle, Idea Education solutions involve training and Management, Change Management and other certification programs and related Quality initiatives . Through research of all best consultancy services supported by research practices being followed at Japan and U.S.A ,he Training & Certification Programs and concentrating on areas of specific has developed a simple, Jargon free ( Joint Certification by LSMI & NCQM) corporate and government development and and integrated 6-level total organisational • Six Sigma Green Belt (ASQ/ Dr.Mikel Harry’s About Us enquiry. Primary purpose of LSMI is to excellence model for organisations to Six Sigma Management Institute) – 4 days provide training and consultancy to become worldclass , suitable for Indian industries and culture . He has deployed Lean • Six Sigma Black Belt (ASQ/SSMI) – 16 days business organisations for improving • Six Sigma Black Belt- DFSS – 5 days quality, productivity and customer Six Sigma initiatives in various organisations across the globe such as SKF, Reliance,Hankel, • Six Sigma Master Black Belt – 20 days satisfaction while reducing cycletime and cost . Xchanging Technology etc. • Lean Expert – 4 days • Statistical Process Control- 3 days About National Centre of Quality He is a Certified Six Sigma Black Belt from ASQ, • Business Process Transformation (BPT)- 1 day Management ( NCQM) : www.ncqm.com QCI & QIMPRO and Certified Master Black Belt • Kaizen basics – 1 day NCQM was established in 1985 by a group of from ISI-Bangalore. He is trained and • Kaizen Event- 5 days eminent industrialists and professionals as Certified on WCM/Lean by Confederation of • Quality Circle – 2days a not-for-profit organization devoted to Indian Industies (CII). He is trained and Certified by AOTS, Japan on Quality Management· He • Measurement System Analysis – 1 day promote quality at National Level. It is a has hands on exposure at Toyota Production • Process capability study – 1 day premier professional institution engaged in promoting Quality culture in Indian Sstems. He has trained more than 1000 Green • Quality Function Deployment- 1 day economy through services like training, Belts and more than 200 Black Belts in DMAIC, • KANO Analysis – 1 day education, seminars, publications, research DFSS and LEAN methodology. He has • Design of Experiment – 3 days and advisory services. completed and coached more than 600 projects • Failure mode and effect analysis- 1 day across various organisations in manufacturing • 5S Workshop – 2days and service areas across the world. He is a • Value Stream Mapping – 1 day certified examiner for RBNQA & CII-EXIM • Problem solving tools – 2 days business excellence award. He is a Sr.Member • Change Management – 1day of ASQ, Six Sigma forum, ISQ, IAOP, ISSP,AIMA, DMA and Centre coordinator of • Lean Six Sigma Overview – 1 day NCQM at Delhi-NCR. • Advance Statistical Tools – 3 days • Cost of Poor Quality (COPQ)- 1 day
  2. 2. ASQ- Green Belt - 4 Days INTRODUCTION PROGRAM CONTENTS The American Society for Quality (ASQ) is the world's DAY- 3 & 4 : leading authority on quality. With more than 100,000 DAY – 1 & 2 : ANALYSE PHASE individual and organizational members, this OVERVIEW-SIX SIGMA Analyze Opportunity – professional association advances learning, improves Six Sigma Overview quality and exchanges knowledge to improve What is wrong? Green Belt - Course Overview business results and to create better workplaces and Six Sigma and organisational goal communities worldwide. Lean principles Exploratory data analysis Design for Six Sigma ( DFSS) Hypothesis testing Certification from ASQ is considered a mark of quality Chi square test excellence in many industries. It helps you advance DEFINE PHASE ANOVA your career and boosts your organization’s bottom line Program Details Define Opportunity – Regression Analysis through your mastery of quality skills. Becoming certified as a Six Sigma Green Belt confirms your What is important? IMPROVE PHASE commitment to quality and will have the positive impact on your organization. Improve Performance – Process Management for projectss PROGRAM OVERVIEW Project management basics What needs to be done? The ASQ Six Sigma Green Belt Program gives Management and planning tools participants the skills and knowledge they need for the Business results and projects Introduction to DOE exceptional leadership of business improvement Team dynamics and performance Full factorial design projects. Upon completing each segment of training, Solution implementation participants immediately apply concepts and tools MEASURE PHASE taught in training to their real-time improvement Measure Performance – CONTROL PHASE projects. How are we doing? Control Performance – Six sigma is a highly disciplined approach used to reduce the process variations to the extent that the How do we guarantee level of defects are drastically reduced to less than 3.4 Process analysis and documentation performance ? per million opportunities (DPMO). Six sigma is a Probability and statistics po wer f ul appr o ach t o achi e ve breakthrough Collecting and summarising data Probability distribution Statistical Process Control (SPC) improvements in manufacturing, engineering and Integrate processes. Service processes. Over the past 20 years, use of Measurement system analysis Process capability and performance Control Strategy Six Sigma, the popular business improvement Close project methodology, has saved Fortune 500 companies a n e s t i m a t e d $ 4 2 7 b i l l i o n
  3. 3. ASQ- Black Belt - 16 Days INTRODUCTION The American Society for Quality (ASQ) is the world's PROGRAM CONTENTS Week- 2&3 : Eight Days leading authority on quality. With more than 100,000 MEASURE PHASE individual and organizational members, this Week- 1&2 : Eight Days Process Characteristics professional association advances learning, improves ENTERPRISEWIDE DEPLOYMENT Data collection quality and exchanges knowledge to improve Measurement systems # Enterprise wide view Black Belt - Course Overview business results and to create better workplaces and Basic statistics communities worldwide. # Leadership Probability Process capability Certification from ASQ is considered a mark of quality ORGANISATIONAL PROCESS ANALYZE PHASE excellence in many industries. It helps you advance MANAGEMENT Measuring and modelling relationships your career and boosts your organization’s bottom line Program Details between variables through your mastery of quality skills. Becoming # Impact on stakeholders Hypothesis testing (Chi-sq, ANOVA) certified as a Six Sigma Green Belt confirms your # Critical to X (CTX) requirements FMEA commitment to quality and will have the positive # Benchmarking Additional analysis methods impact on your organization. # Business performance measures IMPROVE PHASE # Financial measures Design of Experiment (DOE) PROGRAM OVERVIEW The ASQ Six Sigma Green Belt Program gives waste elimination TEAM MANAGEMENT Cycle time reduction participants the skills and knowledge they need for the exceptional leadership of business improvement Kaizen # Team formation Theory of Constraint projects. Upon completing each segment of training, # Team facilitation Implementation participants immediately apply concepts and tools # Team dynamics Risk analysis & mitigation taught in training to their real-time improvement # Team management CONTROL PHASE projects. # Team decision making tools Statistical Process Control (SPC) Six sigma is a highly disciplined approach used to # Management and planning tools Other control tools (TPM,5S…) reduce the process variations to the extent that the # Team performance evaluation and Maintain control level of defects are drastically reduced to less than 3.4 rewards Control plan per million opportunities (DPMO). Six sigma is a po wer f ul appr o ach t o achi e ve breakthrough DFSS DEFINE PHASE Common DFSS Methodology improvements in manufacturing, engineering and Voice of Customer Design for X (DFX) Service processes. Over the past 20 years, use of Project charter Robust design and process Six Sigma, the popular business improvement Project tracking Special design tools methodology, has saved Fortune 500 companies a n e s t i m a t e d $ 4 2 7 b i l l i o n
  4. 4. Lean Expert - 4 Days INTRODUCTION. COURSE DURATION PROGRAM CONTENTS Lean focuses on three things- Elimination 4 days of Waste and Non Value Added activities, WHO SHOULD ATTEND brings process speed and establish the flow. Managers, change agents, Lean Six Sigma Lean evolution It evaluates the entire operation of the practitioners or others that desire an Toyota Production System factory and restructures the manufacturing/ Lean overview Lean Expert - Course Overview understanding of Lean principles service method in order to reduce wasteful COURSE INCLUDES Integration of Lean into Six activities like waiting, transportation, Training Handouts Sigma material hand-offs, inventory, over- Training Completion Certificate Baseline assessment production, etc. It co-locates the processes Certified Lean Expert Certificate on Product and service family in sequential order. As such, it reduces successful completion of training , test & Voice of the customer analysis Program Details variation associated with manufacturing one Lean project Supply Chain Mapping routings, material handling, storage, lack of Project coaching Value stream Mapping communication, batch production etc. Lean WHAT YOU WILL LEARN Product flow analysis methodology focuses on product flow and How to apply Lean methods to improve Operators activity analysis on the operator. How can we produce the response to customers’ requirements in Set up time reduction/ SMED product in the least amount of time, and timelines, quality and cost needs Standardisation how do we standardize the operator How workflow fits into the roadmap to Pull system/ KANBAN methods and give the operator what he/she deploy Lean in an organization. Mistake proofing/Poka yoke needs? How Lean and Six Sigma Cell design and implementation complement each other. Cell performance measurement How waste, value-added and non Continual improvement value-added activities affect process Case studies and Simulations efficiency. How to construct a Value Stream Map to identify areas for improvement. How to determine Lean opportunities vs. Six Sigma opportunities. How to balance workload among employees How to standardise processes and systems
  5. 5. Black Belt (DFSS) - 5 Days INTRODUCTION. PROGRAM CONTENTS COURSE DURATION Companies that excel at designing 5 days DEFINE PHASE DESIGN PHASE more effective ways of accomplishing WHO SHOULD ATTEND Build system and sub-system Black Belt (DFSS) - Course Overview basic business tasks are best poised Six Sigma Green Belt/ Black Belt Identify product/process to excel in today’s competitive who has completed at least one performance models business environment. project Project charter & CTQs Generate transfer function COURSE INCLUDES Set quality goals Statistical analysis and variance Design for Six Sigma’s DMADOV Training Handouts Quality function Deployment drivers Design of experiment (Define-Measure-Analyze-Design- Training Completion Certificate (QFD)- House of Quality- 1 Axiomatic design Optimise-Verify) methodology is a Certified Black Belt (DFSS) Kano analysis Function audit powerful tool for improving innovation Certificate on successful Survey design Process capability flow up for all Program Details and design. This program helps Six completion of training & test subsystem Sigma practitioners apply DFSS WHAT YOU WILL LEARN MEASURE PHASE concepts so that they can foresee How to design new products CTQ flow down and transfer OPTIMISE PHASE and eliminate defects before and using the DMADOV methodology. Function structure Optimise design during the design process. When to use DMADOV over Six Measurement system analysis Statistical tolerancing Sigma’s DMAIC process. Capability study Modeling and sensitivity This five-day program is designed Practical applications of DFSS Taguchi robust design to help participants master a variety tools. ANALYZE PHASE Error proofing of techniques for the design process. Robust Design of Experiments QFD- House of quality- 3 & 4 Develop conceptual designs DFSS is built around the idea that (DOE) techniques. VARIFY PHASE Innovation and creativity “design” is truly a cross-functional Product tolerance analysis Six thinking hats undertaking. No longer is it the sole including the Monte Carlo Product/process design TRIZS/ TIPS responsibility of the “Product Simulation. varification Design for reliability Designer” . While the course focuses How to properly analyze Develop manufacturing & DFSS Score card on statistical design tools, it also reliability data. suppliers control plans Risk assessment emphasizes project management and How to apply the principles of Document and transition Design FMEA includes an in-depth discussion of Design for Manufacturing & Pugh matrix topics such as listening to and Assembly (DFMA). QFD- House of quality- 2 understanding the customer, How to select appropriate Converting customer requirement to maintenance strategies for process specifications and defect free products. des ign right at the f irst time .
  6. 6. Master Black Belt - 20 Days INTRODUCTION. COURSE DURATION PROGRAM CONTENTS A master black belt is very highly 20 days Spread across 4 months Week- 3 : proficient in the six sigma tools and WHO SHOULD ATTEND Week- 1 : DOE – Full factorial Master Black Belt - Course Overview can train others in the methodology. Six Sigma Black Belt who has MBB Introduction DOE-Fractional factorial Number of master black belts may completed at least one project MBB Program review DOE- Aliasing be very few in the organisation. COURSE INCLUDES Presentation skills DOE- Blocking Training Handouts Message maps DOE- Centre point Our Master Black Belt program Training Completion Certificate T-MAP DOE- Response surface is designed to help Black Belts Certified Master Black Belt SIPOC design transition into the Master Black Certificate on successful P-MAP DOE- Mixture design Belt role by providing them with all completion of MBB Criteria FMEA Program Details DOE- Axiomatic design the tools they need to be successful WHAT YOU WILL LEARN Variation and statistics DOE- Orthogonal array teachers, coaches, project leaders How to manage the change Distribution and designs and Champions. These courses How to create infrastructure for transformation DOE- Taguchich designs help practitioners build a mix of both Lean Six Sigma initiatives MSE-Variable Other optimisation techniques hard and soft skills. How to select business critical MSE- Attribute projects Effective team Week-4 : How to conduct GB/BB training Change leadership MBB- Lean Manufacturing How to guide and coach the MBB-Lean services projects Week-2 : Creativity tools How to integrate Lean Six Sigma Sampling & CLT Six thinking hats with other existing best practices MBB-Capability study Lateral thinking How to institutionalise change Parametric hypothesis TRIZ management testing Innovation MBB CERTIFICATION CRITERIA Non parametric hypothesis MBB- DFSS testing MBB-Six Sigma Complete 4 weeks of MBB Turkey test deployment workshop training MBB-ANOVA MBB- Institutionalisation of Co-teach one complete GB/BB MBB-Regression six sigma program with LSMI MBB MBB- Practice sessions on Coach and mentor 2 BB projects teaching, project coaching Complete one MBB project
  7. 7. Statistical Process Control - 3 Days INTRODUCTION. COURSE DURATION PROGRAM CONTENTS Statistical methods are effective tools for 3 days improving the process and reducing the Introduction to SPC defects. People often try to reduce defects by WHO SHOULD ATTEND Basic statistics tracing directly back to the cause of the defect. Managers, Process Engineers, change agents, Basic characteristics of the process This is a straight forward approach and , at a Lean Six Sigma practitioners or others that Sampling & data collection plan glance, it seems to be efficient. But, in most desire an understanding of SPC Pareto analysis cases , causes the causes obtained from that Cause and effect diagram SPC - Course Overview approach are not true ones. Attempts bacome COURSE INCLUDES Histogram abortive and the effort wasted Training Handouts Scatter diagram Training Completion Certificate Process Capability study Program Details Minitab guide Basics of control charts Certified SPC professional Run chart Statistical tools lend objectivity accuracy to I-MR chart observations. The maxims of statistical way of WHAT YOU WILL LEARN X bar- R chart thinking are : Understanding of basic statistics X bar-S chart How to know the current Attribute control charts 1. Give greater importance to facts than capability of the processes P- Chart abstract concepts How to enhance process C- Chart 2. Do not express facts in terms of senses or capability NP- chart ideas . Use figures derived from specific How to identify the problem areas U-Chart observational results How to prioritise the problem areas Introduction to Minitab 3. Provides you adequate informations to take How to set a stretch target Methodology to deploy SPC correct decisions How to take identify the root cause Case Studies Basic problem solving tools This three days training program aims to How to monitor and control the process illustrate the application of statistical methods to real world problems with case studies SPC PROFESSIONAL CERTIFICATION CRITERIA Completion of training Test Score >70%
  8. 8. Business Process Transformation- 1 Day INTRODUCTION. COURSE DURATION PROGRAM CONTENTS Operations are composed of processes that 1 day add value. Enhancing processes can contribute WHO SHOULD ATTEND Create Process Mission to the success of organizations. Step-by-step Managers, Process Engineers, change agents, Document Process- SIPOC approach to process analysis ensures better Lean Six Sigma practitioners or others that Document process – AS-IS success.These steps are: desire an understanding of Business Process Value stream mapping Transformation methodology DocumentCustomer&Process 1. Define the problem COURSE INCLUDES requirements BPT - Course Overview 2. Gather data to describe the problem Training Handouts Identify Output & Process Measures 3. Determine possible causes Training Completion Certificate Build process management system 4. Select the root cause Certified BPT professional Establish data collection plan Program Details 5. Develop solution strategies Process performance monitoring 6. Test and evaluate solutions WHAT YOU WILL LEARN Develop dashboards with spec limits What is difference between activity, process & & targets Constant change is new reality in the world of system Identify improvement opportunities business. A systematic process analysis What is process maturity model methodolog y helps identify and correct How processes mature over a period of time bottlenecks and helps in eliminating any waste. How to identify L-1, L-2, L-3… Processes Process analysis activity should be undertaken How to transform process through 10 step on a regular basis to help in increasing the model of BPT capacity, take full advantage of the processes, How to manage process through metrics improve throughput and reduce cycle time management How to identify potential improvement projects How to prioritise of improvement projects How to involve employees in BPT BPT PROFESSIONAL CERTIFICATION CRITERIA Completion of training Test Score >70%
  9. 9. Kaizen Basic Training- 1 Day Kaizen Event – 5 Days INTRODUCTION. COURSE DURATION PROGRAM CONTENTS Kaizen comprises Japanese words kai and zen 1 day where kai means change and zen means good. WHO SHOULD ATTEND Kaizen Introduction The popular meaning is continuous Managers, Process Engineers, change agents, Kaizen Infrastructure set up improvement of all areas of a company not just Lean Six Sigma practitioners, people at shop 6- level kaizen deployment model quality . Kaizen focuses on waste , delivering floor or others that desire an understanding of Identification of seven types of waste value to customer and create value in process. Kaizen methodology Kaizen Issue identification workshop Kaizen - Course Overview COURSE INCLUDES Kaizen Improvement workshop 1 day basic training give the familiarisation to Training Handouts Kaizen review workshop Kaizen and preparation to launch ‘Kaizen Training Completion Certificate Kaizen event planning and execution Events’ in any organisation or process. 5 days Certified Kaizen professional Kaizen certification to teams Program Details ‘Kaizen event’ some times called ‘Kaizen Blitz’ Kaizen integration with existing other Provides a well planned , focused and rapid WHAT YOU WILL LEARN best practices approach to eliminating waste in the process. How to launch KAIZEN How to involve 100% employees in Kaizen Kaizen builds up quality culture in the How to create an infrastructure for Kaizen organisation by involving all employees in How to measure the benefits of Kaizen continual improvement process focuses on What are six levels of Kaizen continual small, small improvements in day to day basis improvement process towards world class organisation How to conduct ‘Kaizen Events’ How to plan for ‘Kaizen Events’ How to get buy-in from top management KAIZEN PROFESSIONAL CERTIFICATION CRITERIA Completion of training Test Score >70%
  10. 10. Quality Circle - 2 Days INTRODUCTION. COURSE DURATION PROGRAM CONTENTS 2 days Origin and objectives of QC teams that follow a standard process of WHO SHOULD ATTEND 10 elements of successful QC problem identification, root cause analysis, Managers, Process Engineers, change agents, Infrastructure set up for QC problem solving and implementation. In Roles of coordinator, facilitator, Quality Circle - Course Overview Lean Six Sigma practitioners, people at shop Japanese firms there is a greater focus on floor or others that desire an understanding of leader and team members statistical quality control, employees meet on Quality Circle methodology How to conduct QC meetings ? own time and discuss on their own issues and COURSE INCLUDES QC and personal growth identify solutions on the issues. In Japan it is Training Handouts Problem solving tools and also called as Quality Control Circle (QCC) Training Completion Certificate methodology Certified Quality Circle professional Identification of problem Program Details Quality Circle builds up quality Prioritisation of problem culture in the organisation by involving all WHAT YOU WILL LEARN Defining problem employees in continual improvement process How to set up infrastructure for Quality Circle Analysis of problem focuses on small improvements in day to day How to get commitment from management Identification of root causes basis. Management coordinate and facilitate and employees Developing solution the activities of Quality Circle. To enhance the How to involve employees in continual Resistance management effectiveness of Quality Circle, one middle improvement process Implementation of solution management person should act as a facilitator How to select QC projects Benefit validation for each Quality Circle. It’s a great tool to How to conduct QC meetings Follow up and review motivate and empower employees at shop What is the QC problem solving methodology Evaluation criteria of QCFI for floor. How to validate the benefits and sustain it national and international What are the criteria of evaluation to competitions participate in national and internation Workshop competitions Case studies How the initiative is deployed in other organisations QUALITY CIRCLE PROFESSIONAL CERTIFICATION CRITERIA Completion of training Test Score >70%
  11. 11. Measurement System Analysis - 1 Day INTRODUCTION. COURSE DURATION PROGRAM CONTENTS A Measurement System Analysis, 1 day Introduction abbreviated as MSA, is a specially designed WHO SHOULD ATTEND Gause R & R vs MSA experiment that seeks to identify the Managers, People from Quality Control, R & X Bar- R chart components of variation in the measurement. D,QA, Process Engineers, change agents, Lean ANOVA Just as processes that produce a product may Six Sigma practitioners or others that desire an Components of a measurement vary, the process of obtaining measurements understanding of MSA methodology system and data may have variation and produce COURSE INCLUDES Planning for MSA MSA - Course Overview defects. A Measurement Systems Analysis Training Handouts Sampling methodology evaluates the test method, measuring Training Completion Certificate Stability error instruments, and the entire process of obtaining Minitab software application Discrimination error Program Details measurements to ensure the integrity of data Certified Measurement System Analyst Linearity error used for analysis and to understand the Repeatability & Reproducibility implications of measurement error for decisions WHAT YOU WILL LEARN Accuracy vs Precision made about a product or process. MSA is an Why we need MSA? Precision to Tolerance ratio important element of Six Sigma methodology What is relationship between MSA & process Minitab software application and of other quality management systems. improvement? No. of distinct catagories MSA analyzes the collection of equipment, What are different types of MSA? Study variation operations, procedures, software and What are various types of measurement Error %age contributed my personnel that affects the assignment of a errors? measurement system number to a measurement characteristic. A How to quantify those errors ? Workshop Measurement Systems Analysis considers the How to eliminate those errors ? Case studies following: selecting the correct measurement What are the pre-cautions need to be taken to and approach, assessing the measuring avoid those errors ? device, assessing procedures & operators, assessing any measurement interactions, and MEASUREMENT SYSTEM ANALYST calculating the measurement uncertainty of CERTIFICATION CRITERIA individual measurement devices and/or measurement systems. Completion of training Test Score >70%
  12. 12. Process Capability Study - 1 Day Process Capability Study - Course Overview INTRODUCTION. COURSE DURATION PROGRAM CONTENTS Over a period of time inefficiencies built into 1 day Introduction each and every process. Hence measurement WHO SHOULD ATTEND Pre-requisite of capability study of Process Capability for each and every Managers, Process Engineers, change agents, Understand Voice of the Customer process at a regular interval is very essential . Lean Six Sigma practitioners or others that (VOC) This also help to increase efficiency and desire an understanding of process capability Understand Voice of the Process improve the process on regular basis. methodology (VOP) COURSE INCLUDES Process Capability (Cp) Process capability Studies are conducted Training Handouts Process Capability Index (Cpk) to obtain early information on the performance Training Completion Certificate Capability vs Performance of new or revised processes relative to internal Minitab software application Relationship between Cp , Cpk & Pp, Program Details or customer requirements. In many cases, Certified Process Capability Analyst Ppk preliminary studies should be conducted at WHAT YOU WILL LEARN Sigma level of process several points in the evolution of new What is Voice of Customer (VOC)? Minitab software applications processes (e.g., at the equipment or tooling What is Voice of Process (VOP) ? Process Capability for attribute data subcontractor's plant, after installation at the How to measure capability of the process ? supplier's plant) These studies should be based What is the potential capability of the on as many measurements as possible. process? What are short term and long term capability Chinese Proverb : of process ? If you don’t know where you are going, any Can we meet customer’s requirement with road will do. current process capability? Humphrey Proverb : Do we need investment to enhance If you don’t know where you are, a map process capability and satisfy customer ? What is current sigma level and defect level of won’t help. the process ? What actions we need to take to enhance process capability ? PROCESS CAPABILITY ANALYST CERTIFICATION CRITERIA Completion of training Test Score >70%
  13. 13. Quality Function Deployment (QFD) - 1 Day INTRODUCTION. COURSE DURATION PROGRAM CONTENTS QFD was first conceptualized in 1966 as a 1 day Introduction method or concept for new product WHO SHOULD ATTEND Tools to capture voice of the development under the umbrella of Total Managers, Design engineers, People from Sales customer Quality Control, hinshitsu tenkai (quality & Marketing, R & D, Process Engineers, change House of quality deployment) and was developed by Dr. Shigeru agents, Lean Six Sigma practitioners or others QFD & Quality table Mizuno and Yoji Akao. The Japan Society of that desire an understanding of Quality Function Required items to required quality Quality Control formed a research group to Deployment methodology Quality deployment table QFD - Course Overview specifically study Quality Function Deployment COURSE INCLUDES Quality element deployment table (QFD) in 1978. QFD is used to translate Training Handouts Planned Quality vs Design Quality customer requirements to engineering Training Completion Certificate Benchmarking Program Details specifications. It is a link between customers - Certified QFD Professional Target setting for development & design engineers - competitors -manufacturing. WHAT YOU WILL LEARN Improvement It provides an insight into the whole design and What is Voice of Customer (VOC)? Survey for troubles and claims manufacturing operation from concept to How to capture VOC ? Survey for current technology and manufacture and it can dramatically improve How to convert language of customer to equipment the efficiency as production problems are processl language or Critical to Quality (CTQ) Selection of technology tasks resolved early in the design phase. parameters Resolution of technology task What is house of Quality ? Rewrite Quality table It is very powerful as it incorporates the Steps to prepare house of Quality ? Quality Assurance characteristics voice of the customer in the designs - hence it How to built quality into the product right in Process planning is likely that the final product will be better design stage ? QC Process chart designed to satisfy the customer's needs. How to make product /service right at the first Standard Operating Procedure Moreover, it provides an insight into the whole time ? Benefits design and manufacturing operation (from How to bring in ‘ZERO’ defect concept to concept to manufacture) and it can dramatically process ? improve the efficiency as production problems are resolved early in the design phase. QFD PROFESSIONAL CERTIFICATION CRITERIA Completion of training Test Score >70%
  14. 14. KANO Analysis - 1 Day INTRODUCTION. COURSE DURATION PROGRAM CONTENTS In the late 1970s Dr. Noriaki Kano of Tokyo 1 day Introduction to KANO analysis Rika University further refined the notion of WHO SHOULD ATTEND KANO Model quality derived partially from his study of Managers, Design engineers, People from R & Value & Value stream KANO Analysis - Course Overview Herzberg's "Motivator-Hygiene Theory" and re- D, Process Engineers, change agents, Lean Six Reactive vs Proactive mode of voice defined quality along two dimensions in Sigma practitioners or others that desire an of the customer contrast to the linear "good-bad" "ok-not ok" understanding of process capability KANO survey dimension in existence all along. The two methodology Designing questionnaire dimensions were: 1) the degree to which a COURSE INCLUDES Conduct survey product or service performs, & 2) the degree to Training Handouts Analysis of the survey which the user is satisfied. The correlation of Training Completion Certificate Preparation of Multi Generation Program Details quality on two axes further led to three unique Certified KANO Analysis Professional Product Plan ( MGPP) definitions of quality, namely: WHAT YOU WILL LEARN Integration with process parameters How to determine value to customer? through QFD • Must-be requirements of Customer What is Value & Value stream ? Workshop ( Basic quality) What are various types of customer Case Studies • One Dimentional requirements of requirements ? Customer (Performance quality) How best we can capture requirements of • Delighter requirements of Customer customer ? (Excitement quality) How to conduct survey ? How to analyse results & take action ? This analysis is useful to capture voice of the How to integrate VOC (Voice of Customer) customer , various types of customer with VOP(Voice of process) & VOD (Voice of requirements . KANO analysis helps us to in design) product/service design and preparing Multi Generation Product Plan (MGPP) KANO ANALYSIS PROFESSIONAL CERTIFICATION CRITERIA Completion of training Test Score >70%
  15. 15. Design of Experiment (DOE)- 3 Days INTRODUCTION. COURSE DURATION PROGRAM CONTENTS DOE is a systematic approach of investigation of 3 days a system or process. A series of structured tests WHO SHOULD ATTEND Introduction to DOE are designed in which planned changes are made Managers, Process Engineers, R & D people, One factor at a time (OFAT) to the input variables of a process or system. The change agents, Lean Six Sigma practitioners, or Fractional factorial design effects of these changes on a pre-defined output others that desire an understanding of DOE Aliasing are then assessed methodology Fractional factorial design . COURSE INCLUDES Placket Burman design DOE - Course Overview Training Handouts Blocking DOE is important as a formal way of Training Completion Certificate Centre point maximizing information gained while resources Certified DOE professional Response Surface Design (RSD) Program Details required. DOE can be used to find answers in WHAT YOU WILL LEARN Mixture design situations such as "what is the main contributing How to find out ‘Vital few’ causes from ‘Trivial Orthogonal Array(OA) design factor to a problem?", "how well does the Many’ scientifically ? Taguchi robust design system/process perform in the presence of How to exactly identify the effect of factors on Other optimisation techniques noise?", "what is the best configuration of factor responses ? values to minimize variation in a response?" etc. How to identify the effect of interaction In general, these questions are given labels as between the factors on responses ? particular types of study. In the examples given How to plan for a DOE ? above, these are problem solving, parameter How to execute DOE ? design and robustness study. Which type of DOE need to be selected for which problem ? How to optimise factor settings to get maximum output ? How to optimise the composition of the mixture/solution to get maximum response ? How to set parameters to design a robust process ? DOE PROFESSIONAL CERTIFICATION CRITERIA Completion of training Test Score >70%
  16. 16. Failure Mode & Effect Analysis (FMEA)- 1 Day INTRODUCTION. COURSE DURATION PROGRAM CONTENTS Failure Mode and Effects Analysis is a 3 days systematic technique which identifies and ranks WHO SHOULD ATTEND Introduction to FMEA the potential failure modes of a design or a Managers, Process Engineers, R & D people, FMEA and it’s applications process in order to prioritize improvement change agents, Lean Six Sigma practitioners, or Types of FMEAs Actions others that desire an understanding of FMEA Steps to make FMEA methodology Process Mapping FMEA is an important analysis tool bacause COURSE INCLUDES Controllable and Noise factor FMEA - Course Overview – Training Handouts Potential failure modes Training Completion Certificate Effect of failure • It is used to predict and prevent process Certified FMEA professional Determination of causes of failure Program Details defects WHAT YOU WILL LEARN Various levels of control in process How to pre-screen process inputs for problem Risk Priority Number (RPN) • It helps in predicting process faults before a solving ? Rating scale for Severity, Occurance change is made or before a process is started How to identify quick hit actions ? & Detectability How to identify potential failure modes in Action planning • It is most helpful in process development stage process/design ? Post RPN , even before the process is begun How to prioritise risk mitigation efforts ? Design FMEA How FMEA can be used for new product Process FMEA /process design ? How FMEA can be used to solve problems in existing process ? FMEA PROFESSIONAL CERTIFICATION CRITERIA Completion of training Test Score >70%
  17. 17. 5S WORKSHOP - 2 Days INTRODUCTION. COURSE DURATION PROGRAM CONTENTS 5S is a Japanese concept of better workplace 2 days management, comprises of following 5 Ss. WHO SHOULD ATTEND Introduction Seiri (sort), Seiton (set in order), Seiso Managers, Process Engineers, change agents, Preparation for 5S (shine), Seiketsu (standardize), Shitsuke Lean Six Sigma practitioners,Shop floor people Infrastructure for 5S (sustain) or others that desire an understanding of 5S Sorting methodology Set in order The 5S - Campaign is a common action for COURSE INCLUDES Shining everyone to create tidy and clean working area. Training Handouts Standardising 5S - Course Overview The objectives of 5S are – Training Completion Certificate Sustaining • Creation of a clean and more pleasant work Certified 5S professional 5 levels of 5S Program Details environment WHAT YOU WILL LEARN 5S audit • Creation of space and reduction of How to make our workplace spic & span all Workshop archiving the time ? Case studies costs How to do preparation for 5S deployment • Reduction of unnecessary searching How to set up infrastructure for 5S times for sustainance material, documents, etc. How to involve top management in 5S ? Advantages of 5S are - How to involve employee for 5S sustainance ? • Quicker recognition and elimination of How to do documents management ? wastes How to create a clean productive work place • Reduction of disturbances to motivate employees at shop floor ? • Employees feel better on the job • Work environment is presentable to 5S PROFESSIONAL CERTIFICATION customers at any time CRITERIA Completion of training Test Score >70%
  18. 18. Value Stream Mapping (VSM) - 1 Day INTRODUCTION. COURSE DURATION PROGRAM CONTENTS Value Stream Map is a visual tool 1 day used to document the flow of products or WHO SHOULD ATTEND Introduction to VSM ser vices through a system. The VSM Managers, Process Engineers, change agents, Hierarchy of process discovery differentiates the value-adding activities of a Lean Six Sigma practitioners,Shop floor people Product/Service family system from the non-value-adding ones. or others that desire an understanding of VSM Scoping of VSM Recording the time taken for each activity shows methodology Components of VSM what percentage of valuable time an object or Steps to prepare VSM VSM - Course Overview person spends in a system. Any non-value- COURSE INCLUDES Current state map adding time indicates an opportunity for possible Training Handouts Future state map improvement within the system. Training Completion Certificate Opportunities for Improvement Program Details Certified VSM professional Implementation plan Workshop The VSM shows the process flow from WHAT YOU WILL LEARN Case stydies order to delivery and includes - a) information & How value is flowing across the supply chain ? material flow, b) product throughput & cycle How product/service flow is happening in times, c) resources utilized, d) value added times process? and e) location of significant waste . It helps in How information flow is happening in the identifying potential improvement projects need organisation ? How to optimise ? to be taken up to enhance efficiency and What is current state of the process ? effectiveness of the processes. What should be the future state of the process? How to establish flow, reduce inventory, enhance value added percentage in the process? VSM PROFESSIONAL CERTIFICATION CRITERIA Completion of training Test Score >70%
  19. 19. Problem Solving Tools - 2 Days INTRODUCTION. COURSE DURATION PROGRAM CONTENTS Problem Solving Tools - Course Overview In any business endeavor, there 2 days are various processes working simultaneously to WHO SHOULD ATTEND Introduction to problem achieve a certain desired business objectives. Managers, Process Engineers, change agents, Problem definition Any deviation in the outcome of those processes Lean Six Sigma practitioners,Shop floor people 8D approach from the desired outcome can be considered as or others that desire an understanding of Check sheet a defect or a failure or an event or a problem. problem solving tools Pareto chart Cause and effect diagram For every problem, there is at least COURSE INCLUDES Graph & Control Charts one simple, plausible and wrong solution. There Training Handouts Scatter plot are no ‘quick fixes’ to any problem.Quick fixes Training Completion Certificate Histogram Program Details normally results in complacency and false Certified Quality tools professional Stratification security of having cured problem. Thus every Afinity diagram problem needs to be solved in a scientific and WHAT YOU WILL LEARN Force field analysis s y s t e m a t i c m a n n e r . How to identify a problem ? Matrix diagram How to prioritise the problems ? Process Decision Programme Chart How to understand the problem ? Interrelationship digraph What are various basic problem solving tools? Nominal Group Technique What are various management tools ? Tree Diagram What methodology we need to follow to solve the problem ? QUALITY TOOLS PROFESSIONAL CERTIFICATION CRITERIA Completion of training Test Score >70%
  20. 20. Change Management - 1 Day INTRODUCTION. COURSE DURATION PROGRAM CONTENTS Change management is the 1 day Change Management - Course Overview process of developing a planned approach to WHO SHOULD ATTEND Dynamics of change change in an organization. Typically the Top Management, Managers, Process Change model objective is to maximize the collective benefits Engineers, change agents, Lean Six Sigma Steps for leading change for all people involved in the change and practitioners, or others that desire an Establish sense of urgency minimize the risk of failure of implementing the understanding of Change management Create support team change. The discipline of change management methodology Develop vision deals primarily with the human aspect of Communication skills change, and is therefore related to pure and COURSE INCLUDES Resistance management i n d u s t r i a l p s y c h o l o g y Training Handouts Employee empowerment Program Details Training Completion Certificate Create short term wins Change leaders that understand Certified Quality tools professional Team dynamics the phases of transition and are able to apply management strategies for each of the transition WHAT YOU WILL LEARN phases accelerate the time to acceptance which How to manage change in turn results in desired behavior. When do we need change Is change good every time ? What are the steps for change ? How to make change last ? How to plan for change ? CHANGE MANAGEMENT PROFESSIONAL CERTIFICATION CRITERIA Completion of training Test Score >70%
  21. 21. Lean Six Sigma Overview - 1 Day INTRODUCTION. PROGRAM CONTENTS Lean Six Sigma Overview - Course Overview COURSE DURATION Six sigma is a highly disciplined approach 1 day used to reduce the process variations to the Introduction to Lean Six Sigma extent that the level of defects are drastically WHO SHOULD ATTEND History of Lean reduced to less than 3.4 per million opportunities Top Management, Managers, Process Histrory of Six Sigma (DPMO). Six sigma is a powerful approach to Engineers, change agents, or others that desire Lean principles a c h i e v e b r e a k t hr oug h im pr ovem ent s in basic understanding of Lean Six Sigma Types of waste manufacturing, engineering and business methodology Lean Six Sigma Integration processes. It is a new way of doing business that Lean Six Sigma deployment would eliminate the existing defects efficiently COURSE INCLUDES methodology and prevent defects from occurring . Training Handouts Project identification and prioritisation Program Details Training Completion Certificate Black Belt/Green Belt selection Lean evaluates the entire operation Poject execution of the factory and restructures the method in WHAT YOU WILL LEARN DMAIIC Methodology order to reduce wasteful activities like waiting, What is Lean methodology ? Project review transportation, material hand-offs, inventory, Can it be used for transactional processes ? Financial validation of projects over-production, etc. It focuses on product flow What are various types of waste ? Institutionalisation of Lean Six Sigma and operator activity i.e, how can you produce How to create improvement culture in the the product in the least amount of time, and how organisation ? you can standardize the operator methods and What is Six Sigma ? g i ve t h e o p e r a t o r w h at he/ she nee ds? Brief history of Lean & Six Sigma ? . What kind of infrastructure is required for Lean Six Sigma deployment ? What kind of ROI one should target for ? How to select business critical projects ? How to deploy Lean Six Sigma ?

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