6sigma training.pdf

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Fundamentals of
Lean Six Sigma
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Overview
This course is developed to all who wish to understand fundamentals of Lean Six Sigma and its implementation in the Organization, using
Most applicable Lean Six Sigma Tools, Techniques and Templates. This course is comprised of 8 hours.
Who Should Attend?
Supply Chain, Operations, HR, Sales & Marketing, IT, Finance, R&D and Innovation Professionals

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Topics Covered:
• What is Lean Management
• What is Six Sigma
• Six Sigma Meaning
• Six Sigma Old and New Belief
• Myths About Six Sigma
• Benefits of Six Sigma
• Six Sigma – Organization
• Six Sigma – Get Started
• Six Sigma Methodologies
• DMAIC Methodology
• DMADV Methodology
• DFSS Methodology
• Phases of DMAIC, DMADV
• Six Sigma Critical Tools
• Six Sigma Defects Metrics
• Lean Management Tools & Techniques

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Learning Outcomes:
• Define and understand Lean Six Sigma.
• Describe Lean Management, Six Sigma, DMAIC, DMADV Methodology.
• Design DMAIC
• Application of Lean and Six Sigma Tools
• Develop Customized Lean Six Sigma Projects

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What is Six Sigma?
• Introduced in 1986 by American Engineer “Bill Smith”- Father of Six
Sigma at Motorola.
• Six Sigma is a disciplined, data-driven approach and methodology for
eliminating defects.
• 3.4 DPMO (Defects Per Million Opportunities)
• Six Sigma is a set of tools and techniques for process improvement

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What is Lean Management?
Lean management is a business methodology that is design to
increase quality and efficiency of processes by eliminating wasted
resources.
It is also referred to as Lean Manufacturing or Lean Production.

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Six Sigma Meanings
Six Sigma has many meanings
i. A Symbol
ii. A Measure
iii. A Benchmark or Goal
iv. A Philosophy
v. A Method

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Six Sigma – A Symbol
i. Sigma is a statistical symbol for Standard Deviation.
ii. Standard Deviation is a Measure of Variability.

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Six Sigma – A Measure
i. The Sigma Level of a Process can be used to express its
capability (How well is performs with the respect to customer
requirements).
ii. Percent Defects, Cp, Cpk, ppm

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Six Sigma – Calculator
i. 6 Sigma = 3.4 DPMO
ii. 5 Sigma = 233 DPMO
iii. 4 Sigma = 6210 DPMO
iv. 3 Sigma = 66,800 DPMO
v. 2 Sigma = 308,000 DPMO
vi. 1 Sigma = 690,000 DPMO
Sigma Level PPM Percentage
1 691,462 30.9%
2 308,537 69.1%
3 66,811 93.3%
4 6,210 99.4%
5 233 99.98%
6 3.4 99.9997%

Six Sigma Old Vs New Belief
There are two Beliefs
i. Old Belief
(High Quality -> High Cost)
ii. New Belief
(High Quality -> Low Cost)
Internal &
External
Failure Costs
Prevention &
Appraisal
Costs
Old Belief
4s
Costs
Internal &
External
Failure Costs
Prevention &
Appraisal
Costs
New
Belief
Costs
Quality
Quality
Old Belief
High Quality = High Cost
New Belief
High Quality = Low Cost
Sigma is a measure of how much
variation exists in a process
Low
High
High
4s
5s
6s
Figure - 2
Figure - 1

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Myths About Six Sigma
i. Six Sigma is only concerned with reducing defects
ii. Six Sigma is a process for production engineering
iii. Six Sigma cannot be applied to engineering activities.
iv. Six Sigma uses difficult-to-understand statistics.
v. Six Sigma is just a training.

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Key Concepts of Six Sigma
At its core, Six Sigma revolves around a few key concepts.
i. Critical to Quality: Attributes most important to the customers.
ii. Defects: Failing to deliver what the customer wants.
iii. Variation: What the customer sees and feels.
iv. Stable Operations: Ensuring consistent, predictable processes
to improve what the customer sees and feels.
v. Design for Six Sigma: Designing to meet customer needs and
process capability.
Our Customer Feel the Variance, Not the Mean. So, Six Sigma
Focuses on reducing process variation and then on improving
process capability.

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Benefits of Six Sigma
i. Generates sustained success.
ii. Sets a performance goal for everyone.
iii. Enhances Value to Customers.
iv. Accelerates the rate of improvement.
v. Promotes learning and cross-pollination.
vi. Executes Strategic change.

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Six Sigma - Organization
i. Leadership
ii. Sponsor
iii. Implementation Leader
iv. Coach
v. Team Leader
vi. Team Member
vii. Process Owner
viii. Extended Definitions of Roles – Belt Colors

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Six Sigma – Get Started
i. Is Six Sigma right for you?
ii. The Cost of Six Sigma Implementation
iii. Six Sigma Start-up
iv. Project Selection for Six Sigma

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Six Sigma Methodologies
a. DMAIC Methodology
b. DMADV Methodology
c. DFSS Methodology

Control
Improve
Analyse
Measure
Define
SPC
Implementation
Plan
Ishikawa
Diagram
Data
Collection
Project Scope
SOPs
Full Factorial
FMEA
Process Map
Project
Charter
Control Plans
Design of
Experiments
Multivari
Analysis
Control
Charts
Business
Impact
Data
Collection &
Sampling
Brainstorming
and creativity
tools
Hypothesis
testing
Design of
Experiments
Prioritization
Matrix
Voice of
Customer
(VoC)
Affinity
Diagram
Measurement
System
Analysis
Fractional
Factorial
Noise
Variable
Measurement
System
Analysis
Kano Model
Project
Summary
Response
Surface
ANOVA
Process
Capability
CTQ Tree
Lesson Learns
Pilot Trials
Scatter Plots
Yields (RTY)
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i. It refers to data-driven quality strategy for improving
processes.
ii. This methodology is used to improve an existing business
process.
This methodology consists of the following 5 steps.
Define -> Measure -> Analyze -> Improve -> Control

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i. It refers to data-driven quality strategy for designing products
and processes.
ii. This methodology is used to create new product designs or
Process designs in such a way that it results in a more
predictable, mature and defect free performance.
This methodology consists of 5 steps.
Define -> Measure -> Analyze -> Design -> Verify
Control
Improve
Analyse
Measure
Define
SPC
Implementation
Plan
Ishikawa
Diagram
Data
Collection
Project Scope
SOPs
Full Factorial
FMEA
Process Map
Project
Charter
Control Plans
Design of
Experiments
Multivari
Analysis
Control
Charts
Business
Impact
Data
Collection &
Sampling
Brainstorming
and creativity
tools
Hypothesis
testing
Design of
Experiments
Prioritization
Matrix
Voice of
Customer
(VoC)
Affinity
Diagram
Measurement
System
Analysis
Fractional
Factorial
Noise
Variable
Measurement
System
Analysis
Kano Model
Project
Summary
Response
Surface
ANOVA
Process
Capability
CTQ Tree
Lesson Learns
Pilot Trials
Scatter Plots
Yields (RTY)

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c. DFSS Methodology
i. It refers to data-driven quality strategy for designing or
designing a product or service from the ground up.
This methodology can have the following five steps.
Define -> Identify-> Design -> Optimize -> Verify
Control
Improve
Analyse
Measure
Define
SPC
Implementation
Plan
Ishikawa
Diagram
Data
Collection
Project Scope
SOPs
Full Factorial
FMEA
Process Map
Project
Charter
Control Plans
Design of
Experiments
Multivari
Analysis
Control
Charts
Business
Impact
Data
Collection &
Sampling
Brainstorming
and creativity
tools
Hypothesis
testing
Design of
Experiments
Prioritization
Matrix
Voice of
Customer
(VoC)
Affinity
Diagram
Measurement
System
Analysis
Fractional
Factorial
Noise
Variable
Measurement
System
Analysis
Kano Model
Project
Summary
Response
Surface
ANOVA
Process
Capability
CTQ Tree
Lesson Learns
Pilot Trials
Scatter Plots
Yields (RTY)

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This methodology consists of the following 5 steps.
Define -> Measure -> Analyze -> Improve -> Control
1. Define:
Define the Problem and project goal that needs to be
address.
2. Measure:
Measure the problem or process from which it was
produced.
2. Analyze:
Analyze data and process to determine root cause of
defects and opportunities.
4. Improve:
Improve the process by finding solutions to keep the
process on the new course.
5. Control:
Implement, Control, and sustain the improvement
solutions to keep the process on new course.
Control
Improve
Analyse
Measure
Define
SPC
Implementation
Plan
Ishikawa
Diagram
Data
Collection
Project Scope
SOPs
Full Factorial
FMEA
Process Map
Project
Charter
Control Plans
Design of
Experiments
Multivari
Analysis
Control
Charts
Business
Impact
Data
Collection &
Sampling
Brainstorming
and creativity
tools
Hypothesis
testing
Design of
Experiments
Prioritization
Matrix
Voice of
Customer
(VoC)
Affinity
Diagram
Measurement
System
Analysis
Fractional
Factorial
Noise
Variable
Measurement
System
Analysis
Kano Model
Project
Summary
Response
Surface
ANOVA
Process
Capability
CTQ Tree
Lesson Learns
Pilot Trials
Scatter Plots
Yields (RTY)

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1- Define Phase
• Project Team Formation
• Document Customers Core Business Processes
• Develop a Project Charter
• Develop the SIPOC Process Map
• Conclusion

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1- Define Phase
i. Project Charters
ii. Project Decomposition
(a). Work Breakdown Structures (WBS)
(b). Pareto Analysis
iii. Deliverables
(a). Critical to Quality (CTQ) Metrics
(b). Critical to Schedule Metrics
(c). Critical to Cost Metrics
iv. Project Scheduling
(a). Gantt Charts
(b). PERT-CPM
(c). Control & Prevention of Schedule Slippage
(d). Cost Considerations in Project Scheduling
v. Top-Level Process Definition
(a). Process Maps
i. Assembling the Team

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1- Define Phase
Voice of Customer
Learning Objectives
a) Describe the Voice of Customer
b) Explore customer data collection and analysis techniques
i. Defining Customer
ii. Customer Data Collection
iii. Data Collection Methods
iv. Critical Customer Requirements
v. Analyzing Customer Data

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1- Define Phase
Voice of Customer
i. Defining Customer
Primary Customer
• Highest Impact
• Most Important
• Team Consensus
• The External Customer
Types of Customers
• Current, Happy Customers
• Current, Unhappy Customers
• Lost Customers
• Competitor’s Customers
• Prospective Customers

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1- Define Phase
Voice of Customer
Internal Customers
• Employees
External Customers
• End Users
• Intermediate Customers
• Impacted Parties
• External Customer Segmentation
(i- Business ii- Consumer)
i. Customer Data Collection
ii. Data Collection Methods
iii. Critical Customer Requirements
iv. Analyzing Customer Data

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1- Define Phase
Voice of Customer
Customer Imperatives
• Customer Service
• Customer Retention
• Customer Loyalty

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1- Define Phase
Voice of Customer
Role of Customer
• Customer is Critical to Business Success
• Foundation of Company’s Business

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1- Define Phase
Voice of Customer
Sources
• Suppliers
• Internal Process
• Customers
Primary Metrics
• Performance
• Features
• Conformance
• Reliability
• Durability
• Response
• Aesthetics
• Reputation

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1- Define Phase
Voice of Customer
Secondary Metrics
• Defects Per Unit (DPU)
• Defects Per Million Opportunities (DPMO)
• Average Age of Receivables
• Number of Defects Per Length
• Scrap Dollars
• Rework Dollars

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1- Define Phase
Voice of Customer
Types of Data
• Business Level
• Stock Prices, Market Share, Earnings, Revenues
ROI
• Operations Level
• Manage Product Operations, Dealing with
Customer Satisfaction, Overall Product
Performance, Internal Operations Efficiency
etc.
• Process Level
• Internal Matrix

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1- Define Phase
Voice of Customer
Voice of Internal Customer
Voice of External Customer

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1- Define Phase
Voice of Customer
Data Collection Methods
• Surveys
• Focus Groups
• Interviews
• Complaint System
• Market Research
• Shopper Program

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1- Define Phase
Voice of Customer
Critical Customer Requirements
• Determining Critical Customer Requirements
• Customer Expectations
• Customer Needs
• Customer Priorities
• VOC
• Critical to Quality (CTQ) Tree
• CTX Requirements

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1- Define Phase
Voice of Customer
Analyzing Customer Data
• Kano Model
• Quality Function Deployment (QFD) – House of Quality

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1- Define Phase
Voice of Customer
Analyzing Customer Data
• SIPOC
Supplier, Input, Process, Output and Customer

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1- Define Phase
Business Case & Project Charter
Learning Objectives
a) Discuss the Role of Project Charter and Business Case
i. The Elements of Project Charter
ii. Project Charter Dynamics

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1- Define Phase
ii. Project Charter Dynamics
• Charter Negotiation
• Project Performance Measurement
• Project Managers
• Lead Team
• Serve Team
• Manage the Project Plan/Milestones
• Lead Meetings
• Sustain
• Communication
• Project SMART Objectives
• Project Charter Review

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1- Define Phase
ii. Project Review
• Weekly Status Review
• Toll Gate Reviews
• Project Review
• Resource Review
• Assess Project Effectiveness
• Review and Assess Corrective Actions
• Overall Assessment of the Delivered Outcome of the
Project
• Measurement of Project Activity
• What, Why, Timing, Means, Asking for
Help, Reporting Critical Information,
Feedback loop, Corrective Action
• Project Management Tools
• Project Plan Elements, WBS, Project
Documents

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1- Define Phase
ii. Project Review
• Project Plan Elements
• Purpose of Project Planning
• Stages
• Elements
• Scheduling
• Establish Responsibilities
• Tradeoff Methodologies
• Assessing Accomplishments
• Early Detection of Problems
• Corrective Action
• Identifying Future Opportunities

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• Goals
• Role of Team Members
• Milestones
• Required Resources
• Higher Level Risks
• Quality Standards
• Cost of Project
• Communication and Stakeholder Registers
1- Define Phase
i. The Elements of Project Charter
Charter Content
• Purpose Statement
• Objectives
• Business Case
• Problem Statement Project Scope

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1- Define Phase
Project Management Tools
Learning Objectives
a) Discuss the Role of Project Reviews and Project Management
Tools
b) Discuss the importance of project documentation
i. Project Reviews
ii. Project Management Tools
iii. Project Documentation

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1- Define Phase
Project Management Tools
i. WBS
ii. Planning Tools
iii. PERT
iv. CPM
v. Gantt Chart

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1- Define Phase
Project Documents
i. Dashboard
ii. Project Report
iii. RACI Model

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1- Define Phase
Analytical Tools
Learning Objectives
a) Explore Various Analytical Problem--Solving Tools
i. Visual Analytical Tools for Problem Solving
ii. Matrix Related Analytical Tools for Problem Solving

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1- Define Phase
Analytical Tools
ii. Matrix Related Analytical Tools for Problem Solving
• Affinity Diagram

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1- Define Phase
Analytical Tools
i. Visual Analytical Tools for Problem Solving
• Affinity Diagram
• Define the Problem
• List ideas on Cards
• Place the Cards on the Table or Wall
• Arrange Cards into Groups or Patterns
• Identify an Affinity Category for Each Group
• Draw Borders to separate the Groups
• Tree Diagram
• Process Decision Program Chart
• Activity Network Diagram

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2- Measure Phase
• Data Collection Plan and Data Collection
• Data Evaluation
• Failure Mode and Effects Analysis (FMEA)
• Yield to Sigma Conversion Table.

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2- Measure Phase
i. Process Definition
(a). Flow Charts
(b). SIPOC
ii. Metrics Definition
(a). Measurement Scales
(b). Discrete and Continuous Data
iii. Process Baseline Estimates
(a). Enumerative and Analytics Studies
(b). Principles of Statistical Process Control
iv. Estimating Process Baseline Using Process Capability
(a). Capability Analysis

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3- Analyze Phase
• Source Analysis
• Process Analysis
• Data Analysis
• Resource Analysis
• Communication Analysis
• Conclusion

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3- Analyze Phase
i. Value Stream Analysis
(a). Value Stream Mapping
(b). Spaghetti Charts
ii. Analyzing the Sources of Variation
(a). Cause and Effect Diagrams
(b). Boxplots
(c). Statistical Interference
(d). Chi-Square, Student’s T, and F Distributions
iii. Regression and Correlation Analysis
iv. Designed Experiments
v. Analysis of Categorical Data
vi. Non-Parametric Methods

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4- Improve / Design Phase
i. Value Stream Analysis
(a). Value Stream Mapping
(b). Spaghetti Charts
ii. Analyzing the Sources of Variation
(a). Cause and Effect Diagrams
(b). Boxplots
(c). Statistical Interference
(d). Chi-Square, Student’s T, and F Distributions
iii. Regression and Correlation Analysis
iv. Designed Experiments
v. Analysis of Categorical Data
vi. Non-Parametric Methods

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5- Control Phase
• Quality Control
• Standardization
• Control Methods and Alternatives
• Responding when Defects occur
• Conclusion

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5- Control Phase
i. Validating the New Process Or Product Design
ii. Business Process Control Planning
(a). Maintaining Gains
(b). Tools & Techniques for Control Planning
(c). Preparing the Process Control Plan
(d). Process Control Planning for Short and Small Runs
(e). Process Audits
(f). Selecting Process Control Elements
(g). Other Elements of the Process Control Plan

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This methodology consists of 5 steps.
Define -> Measure -> Analyze -> Design -> Verify
1. Define:
Define the Problem and project goal that needs to be address.
2. Measure:
Measure and determine customer’s needs and specifications.
2. Analyze:
Analyze the process to meet the customer’s needs.
4. Design:
Design a process that will meet customer’s needs.
5. Verify:
Verify the design performance and ability to meet customer need.

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c. DFSS Methodology
DFSS is a Separate and emerging discipline related to Six Sigma quality
processes.
This methodology can have the following five steps.
Define -> Identify-> Design -> Optimize -> Verify
1. Define:
Define what the customers want, or what they do not want
2. Identify:
Identify the customer and the project.
2. Design:
Design a process that will meet customer’s needs.
4. Optimize:
Determine process capability and optimize the design.
5. Verify:
Test, Verify and Validate the Design.

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Six Sigma Critical Tools
i. The Critical to Quality (CTQ) Tree
ii. The Process Map
iii. The Histogram
iv. The Pareto Chart
v. The Process Summary Worksheet
vi. The Cause-Effect Diagram
vii. The Scatter Diagram
viii. The Affinity Diagram
ix. The Run Chart
x. The Control Chart
xi. FMEA

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Six Sigma Defects Metrics
i. Defects Per Million Opportunities – DPMO
ii. Total Opportunities – TO
iii. Defects Per Opportunities – DPO
iv. Defects Per Unit – DPO
v. How to Find Your Sigma Level
vi. Simplified Sigma Conversion Table

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Lean Six Sigma | Guidelines
Date: 22nd September 2022 | Thursday
Live Streaming
Link will be shared with Top 100 Registered Participants
Recorded Training Premiere Videos Links
i. Youtube Link
https://www.youtube.com/channel/UCM1sjlrrdDzESP0T7jAiWhQ
ii. Facebook Link
https://www.facebook.com/dngacademy.Official
Final Assessment Link
After Course Completion, result will be shared with you via registered email.
Please contact our VOC Team via dngacademy@yahoo.com; OR info@dngacademy.com;

Thank You
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After Course Completion, result will be shared with you via registered email.
Please contact our VOC Team via
dngacademy@yahoo.com; OR info@dngacademy.com;
www.dngacademy.com
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