Lean Six Sigma

Introduction  

• Development of Quality Thinking  
• The Next Evolution 
• Definition of Six Sigma 
• Six Sigma as a Management philosophy

Why Six Sigma? 

Six Sigma: Key Strategic Concepts 

• Strategic 
• About Customers 
• About Variation 
• About Process and Scientific Investigation 
• About People and Learning Not Cost 

Strategic Six Sigma 

• Introduction 
• Vision, Mission and Values 
• Strategic Objectives 
• Hoshin Kanri and Six Sigma

Customers  

• Introduction 
• Customer Satisfaction and Customer Value 

Variation  

• Introduction 
• Special and Common Cause Variation 
• Process Capability 

Processes and Scientific Investigation 

• Introduction 
• Business Processes: The Reality 
• Scientific Investigation 

People and Organizational Learning  

• Key Six Sigma Roles 
• Belt System Issues 
• Team Work
• People and Change 
• Organizational Learning

Sustainable Six Sigma Deployment 

• Deployment Model: Kotter 
• Deployment Logic: System of Profound Knowledge (SoPK) 
• Steps 1 to 3: Envisioning the Transformation 
• Steps 4 to 7: Enacting the Transformation 
• Step 8: Institutionalize the New System 

Six Sigma Projects: Key Concepts 

• Basic Statistical Concepts
• Variation, the Normal Distribution, DPMO and Sigma Levels 
• The Scientific Method and the DMAIC Cycle 
• The Four Focuses of a Six Sigma Project 
• Process 
• People and Change 

DMAIC  

• Introduction 
• The Define Stage 
• The Measure Stage 
• The Analyze Stage 
• The Improve Stage 
• The Control Stage 

Customer Focus in DMAIC   

• Introduction 
• What Does the Customer Value? 
• What is the Value Stream? 
• What Design/Process Elements Affect Customer requirements?
• Quality Function Deployment

Case study

Variability Reduction in DMAIC 

• Introduction 
• Building and Using Control Charts 
• Responding to Out of Control Conditions 
• Process Capability 
• Responding to Incapable Processes 
• Evaluating the Measurement System 

So Aspects of DMAIC 

• Learning in and Between Projects 
• People in Improvement 

Processes in DMAIC Projects 

• Introduction 
• Supplier-Input-Process-Output-Customer (SIPOC) Diagram 
• Process Flow Chart 
• Value Stream Mapping 
• So Systems Methodology 

DMAIC in Service Organizations 

• Introduction 
• Service is Different 
• The Dimensions of Service Quality 
• Contribution of Six Sigma 
• Potential Modifications to Six Sigma in Service Environments 

Case study

Successful DMAIC Projects 

• Example of a Six Sigma Project 
• Introduction
• Project Background
• Selection of a Quality Characteristic 
• Methodology

Quality by Design (for Six Sigma) 

• Introduction
• The DFSS Process
• Voice of the Customer 
• Impact of Late Design Changes 
• Design for ‘X’
• DFSS Tools

Six Sigma: A Critique 

• Introduction
• Accepted Strengths of Six Sigma
• Reasons for Failure and Critical Success Factors 
• Inherent Conceptual Issues
• Future

Closing

• Learned Lessons
• Program Feedback
• Case study
• Group Discussion & final test