Agenda

Introduction to Six Sigma

Definition of Six Sigma & its relation to Costs and Efficiencies.

Popularity and Application of Six Sigma

Comparisons between typical TQM and Six Sigma Programs.

How to Deploy Six Sigma

Leadership responsibilities

Resource allocation

Data driven decision making

Organizational metrics and dashboards

Six Sigma Projects

Project Focus

Is it a Six Sigma Project?

Customer Focused Projects

Selecting Projects

Estimating Project Benefits

Overview of DMAIC methodology

Project Reporting

DEFINE Stage Tools & Objectives

Define Stage Objectives

Project Charter: Use and Development

Work Breakdown Structure.

Pareto Diagrams.

Process Maps.

SIPOC

Matrix Diagrams

DEFINE: Metrics & Deliverables

Critical to Quality (CTQ) Metrics

Throughput Yield (and comparison to traditional yield)

Rolled Throughput Yield

Normalized Yield

DPMO: Use and Misuse

Sigma Level

Critical to Schedule (CTS) Metrics

Cycle Time

Process Cycle Efficiency

Process Velocity

Overall Equipment Effectiveness (OEE)

Relation of CTQ and CTS Metrics to Critical to Cost (CTC) Metrics

DEFINE: Project Scheduling

Scheduling Project Activities & Events

Gantt Chart

Critical Path Analysis / Activity Network Diagram.

PERT Analysis

DEFINE: Change Management and Six Sigma Teams

Problems with Change

Achieving Buy-In

Team Formation, Rules & Responsibilities

Stages of Team Development

Overcoming Problems

Consensus Building

Affinity Diagram

Nominal Group Technique

Prioritization Matrix

Measure Stage Tools and Objectives

Measure Stage Objectives

Process Definition (Flowcharts, Process Maps, SIPOC)

Metric Definition

Establishing Process Baseline

Enumerative vs. Analytic Statistics.

Process Variation (Deming's Red Bead)

Benefits of Control Charts.

Requirements vs. Control (Tampering)

Control Chart as Process Baseline Tool

MEASURE: X-Bar Charts

Uses / Assumptions

Construction & Calculations.

Assumptions

Rational Subgroups

Sampling Considerations.

Interpretation (including Run Test Rules)

MEASURE: Individuals Data

Uses, comparison with X-Bar chart

Construction, calculations, assumptions, sampling considerations and interpretation:

Run Charts

Individual-X / Moving Range Charts

Moving Average Charts

EWMA Charts.

MEASURE: Process Capability

Histograms Use and Misuse

Probability Plots

Goodness of Fit Tests

Capability & Performance Indices (Relative to Process Control; Interpretation; Estimating Error)

MEASURE: Attribute Charts

Uses

Selection (P, U, Np, C Charts)

Construction & Calculations

Sampling Considerations

Interpretation

Analyze Stage Tools & Objectives

Analyze Stage Objectives

Definition of Waste

Analyzing Process for NVA

Cycle Efficiencies

Lead Time and Velocity

Takt Time

Methods to Increase Velocity

Standardization

Optimization

Spaghetti Diagrams

Level Loading

When are Batches More Efficient?

Setup Reductions

ANALYZE: Regression Analysis

Cause & Effect Diagrams.

Scatter Diagrams.

Correlation, Stratification, Extrapolation

Linear Regression Model

Interpreting the ANOVA Table

Confidence & Prediction Limits.

Residuals Analysis.

Overview of Multiple Regression Tools including Designed Experiments

Improve Stage Tools and Objectives

Improve Stage Objectives

Tools to Prioritize Improvement Opportunities

Defining New Process Flow

Lean Tools to reduce NVA and Achieve Flow

5S

Level Loading

Tools to Define & Mitigate Failure Modes

PDPC

FMECA

Preventing Failures

Reference to Tools for Defining New Process Levels

Control Stage Tools & Objectives

Control Stage Objectives

Methods of Control

Control Plans

Training

Measuring Improvement