12 -15 sessions totaling 25 -30 hours
- Module 1
- Quality & 8 Dimensions of Quality
- Overview on DPO & DPMO
- Activity: What is the current DPO and DPMO?
- What is the financial impact?
- Module 2
- Voice of customer
- SIPOC
- Activity : What are our customers saying?
- Create a SIPOC
- Module 3
- Process map
- Current Process capability
- Specification limits
- Activity : Do we know the manufacturing flow from input to output ?
- What was our FPY for Q1?
- Module 4
- Measurement system analysis
- Gage R&R
- Activity : How do we measure operator efficiency or part to part variation
- Module 5
- Lean overview
- Types of Waste
- Activity : What types of waste do you see in your process ?
- Module 6
- Lean manufacturing tools
- What is Value?
- Activity : What are the tools that are applicable to your organization?
- Module 7
- Value stream mapping
- Difference between VSM and Process flow
- Activity : What types of waste do you see in your process and what is its impact on time/cost?
- Module 8
- Six Sigma overview
- Power of Lean Six sigma
- Activity : Observe both waste and variation in your process
- Module 9
- LSS Tools
- Implementation of 1-2 tools to solve specific problems
- Activity : Use these tools to analyze a practical problem that you are facing
- Module 10
- Push Vs.Pull
- One piece flow
- Level Loading
- Activity : What is your current model of work and how can you use these tools to make it better ?
- Module 11
- Error proofing/Pokayoke
- Jidoka
- Activity : What are the current failure modes in your process which you can error proof ?
- Module 12
- Importance of Visual Management
- 5-S
- Kanban
- Activity : Create a 5S plan for your organization
- Module 13
- Introduction to FMEA
- Activity : Create FMEA for your process
- Module 14
- Importance of score card
- Data management
- Activity : Create a draft report to collate and present data in a meaningful way ( Daily production, Defects etc)
- Module 15
- Six Sigma Project methodology
- When do we do a project ?
- Lean Vs Six sigma
- Activity : what are the current problems in your organization where you can implement Lean or six sigma and why ?
- Module 16
- Continued ... Six Sigma Project methodology
- When do we do a project ?
- Lean Vs Six sigma
- Activity : what are the current problems in your organization where you can implement Lean or six sigma and why ?
- Module 17
- What are the metrics that define the health of your organization and how to balance them ?
- Activity : Design the critical health indicators for your process
- Module 18
- Ways to measure customer satisfaction
- Quality inspection process
- Activity : What is your current defect or return rate ? What is the financial impact ?
- Module 19
- What are the factors that impact the Quality/performance of your product ?
- Activity : Do we know the individual or combined impact of these factors?
- Module 20
- Usage of Six sigma tools to understand the vital X's
- Activity : Understand vital X's that are causing the Y in your organization
- Module 21
- Designing solutions for X's
- Solution prioritization
- Activity : What solutions are applicable to your organization. How easy or difficult is the implementation
- Module 22
- Implementing short term, mid term and long term solutions
- Activity : Calculate the ROI on these solutions
- Module 23
- Measure the process efficiency , post solution implementation
- Activity : Map the improvement to the solutions and monitor the process to measure project success
- Module 24
- Implement controls to ensure that the solutions are sustainable. Build handover plan
- Activity : Create a Control and Handover plan
- Module 25
- Celebrate success by publishing the case study within your organization
- 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.