1. Module 1 HoshinKanri Getting Started
Developing Corporate Behaviour
Module Two: Total Quality Management
Module Three:BalancedScorecards
The Big Picture
Four Perspectives
Building Blocks
Training Plans
Module Four:Business ProcessManagement
Fundamentals
Process Re- Engineering
Gap Analysis
Lean Facilitation
Module Five:BusinessProcessManagement
Process Reflection
Vision Phase
Design Phase
Modelling Phase
Execution Phase
Monitoring Phase
Optimizing Phase
Module Six:History of TQM / Lean / Six Sigma – LeanOverview
About Lean
History Behind Lean
Toyoda Precepts
The Toyota Precepts
Liker’s Toyota Way
Philosophy
Process
People and Partners
Problem Solving
Toyota Production Systems
The Goals of TPS
The First Pillar: Just In Time (JIT)
The Second Pillar: Jidoka (Error-Free Production)
The Foundation of the House
The Toyota Way 4P Model
5 Core Lean Principles
Calculation of Takt Time
Womacks Five Lean Principles
Value
Value Stream
Flow
Pull
Seek Perfection

2. Create Process Flow
Muri Muda Mura
Traditional Vs New Lean Improvements
PDSA Cycle (Plan Do Study Act)
Gemba
Kaizen (Continuous Improvement)
Kaikaku
Kano Diagrams
Basic Characteristics
Satisfiers
Delighters
Applying the Kano Model
Gemba
Genchi Genbutsu
Shojinka
Hanedashi
5 S
Yokoten
Kaizen Blitz – Action Workout
Cross Functional Value Stream / Value Chain Map
Root Cause Analysis of Why Lean Isn’t Sustained at Large Traditional Companies
Root Cause Analysis of Why Lean Processes are Sustained and Improved at Toyota
Roadmap for a Lean Implementation
Module Seven:LeanSix Sigma
About Six Sigma
Common Cause
Special Cause
Tampering
Structural
What is Complexity?
What Causes Complexity?
How to Simplify?
The DMAIC Method
Define:
Measure:
Analyze:
Improve:
Control:
Using the R-DMAIC Model
DMADV
IDOV
DCOV
Six Sigma Definition
Defects per Unit (DPU)
Defects per Opportunity (DPO)

3. Defects per Million Opportunities (DPMO)
Final Yield (FY)
Throughput Yield (TY)
Process Capacity Calculation
Resourcing Requirements Calculation
Six Sigma Opportunities Game
Define
Measure
Analyze
Improve
Control
Lean Six Sigma Costs and Savings
Lean Six Sigma Roadmap
A Roadmap for Implementation
Module Eight:Lean and Six SigmaTools
Action Workouts
Yamazumi Charts
Kano Diagrams
Quality for Deployment
Cause and Effect Diagrams
Failure Modes and Effects Analysis
Pugh Matrix
Autonomation
Continuous Improvement
Continuous Flow
Kaizen Action Workouts
Kaizen Blitzes
Lean accounting
Lean Suppliers
Points of use Storage
Poka Yoke
Pull and Synchronous Scheduling
Quick and Easy Kaizen
Module Nine:Graphical and Statistical Tools
Graphical Tools
Basic Pareto Charts
Advanced Pareto Charts
Advanced Pareto Options
EZ Pivot Charts
Basic Histogram
Histogram & Descriptive Statistics
Histograms & Process Capability
Dot Plots
Box Plots
Normal Probability Plots

4. Run Charts
Overlay Run Charts
Multi-vari Charts
Multi-vari Options
Scatter Plots
Scatter Plot Matrix
Statistical Tools
Sample Size – Discrete
Sample Size – Continuous
Minimum Sample Size for Robust T Test and Anova
Sample T Test and Confidence Interval for Mean
Sample Chi-Square and Confidence Interval for Standard Deviation
Sample F Test and Confidence Intervals (Compare 2 standard deviations)
Proportion Tests and Confidence Intervals
Proportion Tests and Confidence Intervals
Poisson Rate Test and Confidence Intervals
Poisson Rates Test and Confidence Intervals
One way Chi- Square Goodness of Fit Test
One way Chi-Square Goodness of Fit Test Exact
Descriptive Statistics
1 Sample T Test and Confidence Intervals
Paired T Test
2 Sample T Test
2 Sample Comparison Tests
One Way Anova & Means Matrix
Two Way Anova
Equal Variance Tests
Correlation Matrix
Module Ten: MeasurementSystems Analysis andDesignof Experiments
Measurement Systems Analysis
Gage R&R Study (MSA)
Gage R&R Multi Vari & Bar R Charts
Attribute MSA
Create Gage R&R (Crossed) Worksheet
Analyze Gage R&R (Crossed)
Attribute (MSA) Binary
Attribute (MSA) Nominal
Design of Experiments
Two Factor 4 Run Full Factorial
Three Factor 4 Run Half Fraction, Res III
Three Factor, 8 Run Full Factorial
Four Factor 8 Run Half Fraction, Res IV
Four Factor 16 Run Full Factorial
Five Factor 8 Run Quarter Fraction Res III
Five Factor 16 Run Half Fraction Res V

5. Main Effects & Interaction Plots
2 Level Factorial / Screenings Designs
Main Effects & Interaction Plots
Analyse 2 Level Factorial Screening Design
Contour / Surface Plots
Module Eleven:Process Capability
Process Sigma Level – Discrete
Process Sigma Level – Continuous
Process Capability
Process Capability & Confidence Intervals
Histograms & Process Capability
Capability Combination Report (Individuals)
Capability Combination report (Sub-Groups)
Non Normal
Module Twelve:Control Charts
Basic Individual Chart
Basic Count Chart
Control Chart Selection Tool
Individuals
Individuals & Moving Range
X Bar & R
X Bar & S
Attribute Charts
Non Normal
Advanced Charts
Tests for Special Cause Defaults
Module Thirteen:Standards andTools
Module Fourteen:Project Management
Module Fifteen:Data Intergrity andManagement
Training Manuals and Documents for WorkshopAttendees:
1. Lean Sigma Project Professional Yellow Belt Workshop Slide Pack – 560 slides
2. Lean Sigma Project Professional Training Manual – Yellow Belt
3. Lean Sigma Quick Reference Guide
4. Lean Sigma Project Presentation Pack – Yellow Belt
Free Templates:
1. American Productivity Quality Centre – Industry cross functional process
hierachy template
2. Visio cross functional process and value chain template
3. Togaf 9 – Free template courtesy of Orbus software