Introduction to Six Sigma ( 2 hours )

1. History of Quality (Deming, Juran, JIT, Ishikawa, Taguchi, etc.)
2. Evolution of Six Sigma
3. Defining Six Sigma – philosophy and objectives
4. Importance of Six Sigma as a Quality Initiative to achieve organizational goals
5. Overview of Six Sigma DMAIC process

    Setting up and Managing a Six Sigma Project ( 3 hours)

1. Identifying and Documenting stakeholder requirements
1. Identifying stakeholders and customers
2. Data collection and analysis
3. Determining critical requirements
2. Project Selection  Criteria
1. Identifying performance metrics
2. Using Financial criteria to evaluate project benefits
3. Maximizing project benefits for the organization
3. Project Planning
1. Creating Project Charter
2. Creating Project Plan
3. Managing Project Plan
4. Six Sigma Deployment Overview

1. Importance of top management commitment
2. Hierarchy of Six sigma roles and responsibilities
3. Team selection and stages of team evolution
4. Evaluating Team performance
5. Motivation Techniques
6. Conflict Resolution Techniques

5. Risk Management
1. About Risk Management
2. Tools and Techniques for Risk Management
6. Knowledge Management
1. Lessons Learned

    Six Sigma Methodology – Define ( 2 hours )

1.       Overview of Define Phase

2.       Project Charter

2. Defining project charter
3. Developing problem statement

3. Understanding Data

a.       Basics of six sigma – mean, variation and normal curve

b.       Data Types

c.       Defining Metrics

    Six Sigma Methodology – Measure ( 4 hours )

1. Overview of Measure Phase

2. Understanding processes

a. Identifying process inputs and outputs

b. Important Process Tools used in six sigma

                        i. Cause and Effect diagrams

                        ii. Process Maps

                        iii. Flowcharts

                        iv. Brainstorming

3. Process Costs

a. Different types of process costs

b. Cost of Poor Quality (COPQ) definition and categories

c. COPQ used in six sigma

4. Mathematics behind six sigma

            a. Distributions

i. Normal (in detail)

ii. Lognormal

iii Exponential

iv. Binomial

v.        Poison

vi. Chi-square

vii. Student’s T

viii. F Distribution

            b. Probability and Statistics

5. Measurement Systems

            a. Some sample measurement systems

            b. Validating measurement systems

                        i. Gauge R&R study

                        ii. Total Variation in a system

                        iii. Mathematical analysis

    Six Sigma Methodology – Analyze ( 5 hours )

1. Overview of Analyze Phase

2. Failure Mode and Effect Analysis (FMEA)

            a. Critical to Quality Attributes

            b. Risk Priority Number

            c. Example of FMEA

3. Hypothesis testing

            a. Basics of hypothesis testing.

            b. Tools used for hypothesis testing

4. Determining Process Capability

            a. Identifying capable processes

            b. Accessing process capability for continuous and discrete data

    Six Sigma Methodology – Improve ( 4 hours )

1. Overview of Improve Phase

2. Solutions Design Matrix

            a. Overview of Solutions Design Matrix

            b. Mathematical Example

3. Design of Experiments

            a. Terms and Concepts

            b. Types of DOE Experiments

            c. Benefits from DOE

            d. Application of DOE

    Six Sigma Methodology – Control ( 3 hours )

1. Overview of Control Phase

2. Statistical process control

            a. Data collection methodology

            b. Creating a control plan

            c. Using control chart to measure changes

            d. Control Limits and Specification Limits

            e. Unstable processes

3. Lean tools for Process control

            a. 5S

            b. Kaizen

            c. Kanban

            d. Total Productive Maintenance

            e. Cycle time reduction

4. Improving process Capability

5. Sharing Lessons Learned

    Case Study 1 ( 2 hours )