Lean Six Sigma

12 -15 sessions totaling 25 -30 hours

1. Module 1
   1. Quality & 8 Dimensions of Quality
   2. Overview on DPO & DPMO
   3. Activity: What is the current DPO and DPMO?
   4. What is the financial impact?
2. Module 2    
   1. Voice of customer
   2. SIPOC
   3. Activity : What are our customers saying?
   4. Create a SIPOC
3. Module 3    
   1. Process map
   2. Current Process capability
   3. Specification limits
   4. Activity : Do we know the manufacturing flow from input to output ?
      
   5. What was our FPY for Q1?    
4. Module 4    
   1. Measurement system analysis
      
   2. Gage R&R
   3. Activity : How do we measure operator efficiency or part to part variation
5. Module 5   
   
   1. Lean overview
   2. Types of Waste
      
   3. Activity : What types of waste do you see in your process ?
6. Module 6       
   
   1. Lean manufacturing tools
   2. What is Value?
   3. Activity : What are the tools that are applicable to your organization?
      
7. Module 7       
   
   1. Value stream mapping
      
   2. Difference between VSM and Process flow
   3. Activity : What types of waste do you see in your process and what is its impact on time/cost?
      
8. Module 8       
   
   1. Six Sigma overview
   2. Power of Lean Six sigma
      
   3. Activity : Observe both waste and variation in your process 
      
9. Module 9        
   1. LSS Tools
      
   2. Implementation of 1-2 tools to solve specific problems
      
   3. Activity : Use these tools to analyze a practical problem that you are facing 
      
10. Module 10    
    1. Push Vs.Pull
    2. One piece flow
    3. Level Loading
    4. Activity : What is your current model of work and how can you use these tools to make it better ?
       
11. Module 11        
    1. Error proofing/Pokayoke
    2. Jidoka
    3. Activity : What are the current failure modes in your process which you can error proof ?
       
12. Module 12        
    1. Importance of Visual Management
    2. 5-S
    3. Kanban
    4. Activity : Create a 5S plan for your organization
       
13. Module 13        
    1. Introduction to FMEA
    2. Activity : Create FMEA for your process
       
14. Module 14       
    
    1. Importance of score card
    2. Data management
    3. Activity : Create a draft report to collate and present data in a meaningful way ( Daily production, Defects etc)
       
15. Module 15   
    
    1. Six Sigma Project methodology
    2. When do we do a project ?
    3. Lean Vs Six sigma
    4. Activity : what are the current problems in your organization where you can implement Lean or six sigma and why ?
       
16. Module 16        
    1. Continued ... Six Sigma Project methodology
    2. When do we do a project ?
    3. Lean Vs Six sigma
    4. Activity : what are the current problems in your organization where you can implement Lean or six sigma and why ?
       
17. Module 17        
    1. What are the metrics that define the health of your organization and how to balance them ?
    2. Activity : Design the critical health indicators for your process
       
18. Module 18        
    1. Ways to measure customer satisfaction
    2. Quality inspection process
    3. Activity : What is your current defect or return rate ? What is the financial impact ?
       
19. Module 19        
    1. What are the factors that impact the Quality/performance of your product ?
    2. Activity : Do we know the individual or combined impact of these factors?
       
20. Module 20   
    
    1. Usage of Six sigma tools to understand the vital X's
    2. Activity : Understand vital X's that are causing the Y in your organization
       
21. Module 21        
    1. Designing solutions for X's
       
    2. Solution prioritization
    3. Activity : What solutions are applicable to your organization. How easy or difficult is the implementation
       
22. Module 22        
    1. Implementing short term, mid term and long term solutions
    2. Activity : Calculate the ROI on these solutions 
       
23. Module 23        
    1. Measure the process efficiency , post solution implementation
    2. Activity : Map the improvement to the solutions and monitor the process to measure project success
       
24. Module 24        
    1. Implement controls to ensure that the solutions are sustainable. Build handover plan
    2. Activity : Create a Control and Handover plan
       
25. Module 25    
    1. Celebrate success by publishing the case study within your organization
    2. Activity : Create a success story with the problem , approach , solution and key outcomes

Assessment: Every module will have a short assessment of 5 questions, including MCQ's and situational questions. Feedback will be collected from the learners at the end of one week.