The course structure mirrors the step-wise, systematic approach of the Six Sigma (DMAIC) methodology. It takes students from the highly critical "Define" phase to the "Control" phase, emphasizing practical implementation at each stage.
Introduction to Lean Six Sigma
As indicated earlier, the Six Sigma and Productivity Improvement Program does not assume prior knowledge or familiarity with Six Sigma (or Lean Six Sigma). In this introductory segment, participants will get a general overview of the history, origins and conceptual foundations of Six Sigma, with a particular emphasis on DMAIC (Define, Measure, Analyze, Improve Control) methodology, the framework for the entire course, and Six Sigma core principles. Students will also get an up-close look at the various process improvement phases from Define to Control.
Define the Improvement Opportunities
Every successful business enterprise continuously finds ways to maximize profits by operating more efficiently. In this segment, students will learn to identify opportunities for improvement and make the business case for getting buy-in from their stakeholders. Furthermore, the students will now learn how to convert the comments and complaints from frustrated customers into tangible requirements that can be measured and addressed. They will become adept at mapping their current business or manufacturing process, the first step in determining how the work really gets done. This is almost always and eye-opening experience as one discovers numerous improvement opportunities that were once hidden.
Measure your Performance
This is the phase where students learn how to measure the performance of their business processes. In this segment, students learn to determine what indicators should be measured to improve the process and address customer concerns. Furthermore, the students learn how to collect data in order to measure the selected indicators. Initially, the data collected will focus on lead time reduction and quality improvement. Invariably, the students learn to determine the baseline performance in this segment that becomes the standard used to measure improvement.
Analyze your Opportunities
The rubber meets the road in this segment as students learn analytical and statistical techniques used to analyze the data collected in order to identify root cause of problems or issues in a process. These techniques include but are not limited to Regression Analysis, 5 whys, Pareto Chart, Cause and Effect (fishbone) Diagram and Hypothesis Testing. Ultimately, students learn how to validate and verify the root cause after analysis has been completed.
Improve Your Performance
In this segment, students learn how to implement solutions to the validated root causes that data analysis has confirmed by applying tools that include Affinity Diagrams, Failure Mode Effects Analysis (FMEA) and Cost Benefit Analysis; and techniques such as Benchmarking, Brainstorming and solution piloting. The students learn how to evaluate, select and prioritize solutions that will improve performance using techniques such as Benchmarking, Brainstorming and solution piloting. Furthermore, the students learn how to develop the to-be process Map and the plan to implement it.
Control Your Performance
Participants learn the importance of “mistake proofing” a process to prevent defects for occurring in the future. Furthermore, in this segment, students learn how to develop process control plans to ensure that improvements to the process are maintained. To this end, students learn how to implement risk management and process control systems for the process. Also, they learn the importance of documenting the new standards and procedures. In addition, the students learn how to create dashboards to monitor the process and ensure continued success.