Six Sigma Basics : Introduction, Roles & Responsibility

Description

INTRODUCTION

This course on Six Sigma Basics : Introduction, Roles & Responsibility is part of the Six Sigma Specialization series that is designed to give an introductory and intermediate level of familiarization of Six Sigma concepts and tools.

Six Sigma is a systematic improvement process leading to process design / redesign. It uses several statistical tools and is widely applicable to any process – be it in manufacturing or functional areas. The benefits of Six Sigma are widely acknowledged in several industries and for several different processes – many industries have saved many millions of dollars

Six Sigma coupled with other processes like lean manufacturing form a lethal combination leading to radical improvements and huge savings of time, effort and money.

An understanding of the principles is essential for all – both in management and technical workforce.

LEARNING OBJECTIVES

This course covers the Six Sigma Basics : Introduction, Roles & Responsibility. 

Six Sigma is a methodology for improving the performance of any organization by minimizing the defects in its products or services. Every error committed, has a cost associated to it in form of losing customers, redoing a task, replacing a part, waste time/material or losing efficiency.

Sigma (σ) is a statistical term to represent standard deviation which is a measure of variation in a dataset. Higher sigma score indicates better performance or more precise results. Six Sigma implies almost perfect output resulting in only 3.4 defects per million opportunities (DPMO).

DMAIC and DFSS are the elementary methodologies that exist for two potential scenarios

• DMAIC: To modify an existing process or the application of DMAIC
• DFSS: To start a new process from scratch or the application of DFSS

Implementation of Six Sigma: Six Sigma has adopted martial arts ranking nomenclature to define the hierarchy that covers all kinds of business functions. Six Sigma has identified certain roles for its implementation.

• Executive Leadership refers to top management including the CEO. They are the visionaries who authorize other team members and provide them with resources for process improvement.
• Champions or Quality Leaders implement and integrate Six Sigma methodology throughout the organization. They are chosen from the upper management by the Executive Leadership and mentor Black Belts.
• Master Black Belts, identified by Champions, are expert coaches on Six Sigma. They act as guides for Black Belts and Green Belts and assist Champions to implement Six Sigma and integrate the methodology throughout the organization including all departments and their respective functions and processes.
• Black Belts operate under the guidance of Master Black Belts and their task is to apply Six Sigma methodology to various projects specified. Their primary focus is the execution of Six Sigma project, as against to Champions and Master Black Belts who primarily focus on identifying functions and goals for the Six Sigma project.
• Green Belts work on Six Sigma implementation along with other job responsibilities unlike Black Belts, Master Black Belts and Champions who devote 100% of their time on Six Sigma execution. They are guided by Black Belts and provide them support in achieving the desired results.
• Yellow Belts are employees who are trained in Six Sigma techniques, but have not practically applied their knowledge to a Six Sigma project.

We will discuss these topics in this course.  

On completion of this series, the user will have a good knowledge of:

• Tools used in Define stage – Project charter, Thought map, SIPOC, Value Stream Map, Zero Loss studies to identify bottleneck machine / operation (in manufacturing), Cause and Effect matrix, Failure Mode Effect Analysis
• Measuring the process – Measurement System Analysis. This may be more relevant for processes related to manufacturing
• Improvement methods and related statistical tools of Hypothesis testing – Chi squared test, t test, Analysis of variance (ANOVA)
• Control strategies for sustenance of the improvements made by design or redesign of processes

After this series, the participant can appreciate any topic on Six Sigma which are at fundamental or intermediate levels. On completion of the series the participant will be ready to enroll in Advanced courses on Six Sigma that lead to a formal certification as a White Belt or Yellow Belt or Green Belt or Black Belt.

ALL of our courses in this series is developed based on decades of front-line industry experience of the instructor. 

WHO SHOULD TAKE THIS COURSE

Anyone who is involved with any process, be it manufacturing or transactional. It is uniformly applicable across any function. This course is equally important to any operator or management staff.

The series should form mandatory knowledge for any professional in manufacturing or Supply Chain or Project Management or HR or any function and especially a new employee.

This course is ALSO part of the is a Bundled Specialization course titled Six Sigma Specialization. You might also want to consider  to take the course on Lean Manufacturing Tools Specialization along with this course.

COURSE CONTENT 

• INTRODUCTION
• HISTORY
  • Origin of the term
  • History
• WHAT & WHY
  • Strategic Link
  • Reducing Variation
  • Characteristics of Six Sigma
  • Objectives of Six Sigma
• VARIATION
  • Basic Statistics
  • Out of specification
• STAGES
  • DMAIC
  • DMADV
• ROLES
  • Organization
  • Deployment Champion
  • Project Sponsor
  • Master Black Belt
  • Black Belt
  • Green Belt
  • Six Sigma Steering Group
  • Process Owner
  • Controller
  • Project Team
• TEAMS
  • Role of Six Sigma project leader
  • 4 phases of team development
  • Requirements for an effective team
  • Eight rules of leading a team
  • Eight rules of team membership
  • Seven leadership traps
  • Nine membership traps
• CONCLUSION
  • TQM versus Six Sigma
  • Six Sigma projects vs other projects
  • Unique features of Six Sigma projects
  • Six Sigma Project phases
  • Summary – fruits of improvements
• DMAIC ROADMAP
  • DMAIC skeleton
  • Road map for common tool usage
  • Purpose per phase
• REFERENCES & COURSE HANDOUTS
• FINAL QUIZ