Summary of Six Sigma Stages and Tools

Description

INTRODUCTION

This course on Summary of Six Sigma Stages and Tools 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 Summary of Tools and Stages of Six sigma. The Six Sigma DMAIC (Define, Measure, Analyze, Improve, Control) methodology is a roadmap for problem solving and product/process improvement. Most companies begin implementing Six Sigma using the DMAIC methodology, and later add the DFSS (Design for Six Sigma, also known as DMADV or IDDOV) methodologies when the organizational culture and experience level permits.

DMAIC Phase Steps are:

D – Define Phase: Define the project goals and customer (internal and external) deliverables.

M – Measure Phase: Measure the process to determine current performance; quantify the problem.

A – Analyze Phase: Analyze and determine the root cause(s) of the defects.

I – Improve Phase: Improve the process by eliminating defects.

C – Control Phase: Control future process performance.

We will discuss the Steps and Tools used in each of the phases above.  

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
• BASICS
  • Origin of the term
  • History
  • Reducing Variation
  • DMAIC
  • DMADV
  • Six Sigma projects vs other projects
• STATISTICS
  • Sigma Level
  • Out of Specification
• DMAIC ROADMAP
  • DMAIC skeleton
  • Purpose per phase
  • Road map for common tool usage
• DOCUMENTS
  • Charter Structure & Elements
  • Thought Map (T-Map)
  • SIPOC
  • Process and SIPOC form
  • Process Map
  • Cause & Effect Matrix
  • Failure Mode and Effects Analysis
  • How to make FMEA
  • Linking the documents
• MSA
  • Analyze – Generate & Interpret
  • Stability
  • Discrimination
  • Repeatability
  • Product Variation vs. Measurement Variation
  • Reproducibility
  • Reproducibility : Operator Variation
  • Reproducibility : Operator by Part Interaction
  • Attribute Measurement Systems
• HYPOTHESIS TESTING & STATISTICAL TESTS
  • Basic terminology & decision errors
  • Tools for Evaluating X vs Y
  • Chi-square test
  • t-test
  • ANOVA : F-Distribution
  • F-Distribution : Concept Animation
  • ANOVA Options
• CONTROL PHASE
  • Why control phase
  • Control levels
  • Control Plan – components
• STATISTICS – SUPPLEMENTARY TOOLBOX
  • What is statistics
  • Populations and Samples
  • Process Variability & Customer Specifications
  • Shapes of distribution
  • The Normal Distribution
  • Causes of variation
• REFERENCES & COURSE HANDOUTS
• FINAL QUIZ