Course outline

Section 1: The Six Sigma Environment

• What is the six sigma philosophy
  Improve profitability, be customer focused, measure outcomes, focus on prevention, and reduce variation.
• What are the basic concepts of Six Sigma?
  Use data, track defects per million opportunities (DPMO), understand the cost of quality (COQ), focus on elements that are critical to quality (CTQ), use facilitation as applied training, assure an acceptable return is achieved on your investment, link performance with rewards.

Section 2: Six Sigma Tools

• Statistical tools
  Statistical process control charts, process capability (Cr, Cp, Cpk, Pp, Ppk), measurements systems analysis (gage R&R, measurement uncertainty), statistical analysis (correlation analysis, test of significance, ANOVA), and design of experiments (DOE).
• Problem solving
  The 8-Discipline Method, cause-and-effect diagrams, brainstorming, PERT charts, and Gantt charts.
• Root cause analysis
  5-Whys, What is-What isn't analysis, timeline analysis, and fault tree analysis.
• Lean thinking
  Workflow analysis, one-piece flow, kanbans, TAKT time, and setup reduction.
• Process improvement
  Failure mode and effects analysis (FMEA), mistake-proofing, 5-Ss for workplace organization, total productive maintenance (TPM), and setup reduction.
• Data analysis and display
  Pie charts, bar charts, histograms, Pareto analysis, scatter diagrams, trend charts, and concentration diagrams.
• Process mapping
  Test of significance, musts and wants, nominal group technique (NGT), and voting and ranking.
• Product process interaction
  Quality function deployment (QFD), FMEA, DOE, and design for manufacturing, assembly, and environment (DFX).

Section 3: The Six Sigma Infrastructure

• Design the organization
  Leadership team, mentors and coaches, Black Belts, teams and projects, DMAIC and DMAIV models, and roll-out.
• Establishing the support system
  Boundaries of freedom, best practices forum, teamwork and conflict resolution, visual factory, recognition.
• Project management process
  Project identification, selection, reviews, and solutions.
• Linking performance and rewards
  Recognition vs. rewards, compensation, and performance.
• Setting metrics
  DPMOs, baseline and trends, balanced scorecard, and benchmarks.
• Providing training
  Basic, intermediate and advanced tools, training methods, training plan, facilitation, resources.