Lean and Six Sigma

Product Note – Lean Methodology

Introduction

Lean is a principle drove, Tool based Process Re-engineering/Improvement/Excellence Methodology that focusses on eliminating Waste from your existing processes to deliver products and services at the faster pace using lesser resources and thereby bringing significant efficiencies and cost benefits into the system.

Applicability

  1. Lean can be used in both Manufacturing and Service Industries and is generally applied to problems with known causes and complex solutions.
  2. Eg: Building a Flyover, Medical Insurance Claim Processing.

Learning Objectives

  1. Understand Thoroughly What is Lean, Its associated principles and Tools
  2. Where to apply Lean Principles & Tools and their Benefits.
  3. How to Implement Lean in your work environment

Who Should Attend

Assistant Managers & above in all departments including Operations & Support Functions

Pedagogy

Classroom Training Involving PowerPoint Presentations & Videos

Duration

500 Minutes

Difficulty

Basic

Assessment

Learning Access

Certified/Accredited By

MAGE

Serial No Index Time
A Introduction 5
B Purpose 10
C What is Lean? 60
1 Introduction To Lean
2 Difference Between Lean & Six Sigma
3 When To Use Lean?
4 History of Lean
5 Toyota Production System
D 5 Principles of Lean & Associated Tools 5
1 Specify Value 10
2 Identify The Value Stream 60
a Value Stream Mapping
b 8 Different Wastes – Muda, Mura, Muri
c Current State >Wastes>Future State
3 Create Flow
a Takt Time
b Single Piece Flow
c Just In Time
d Jidoka
e Heijunka
f Standard Work
g Overall Equipment Effectiveness
h Cellular Manufacturing
i Single Minute Exchange of Die (SMED)
j Total Productive Maintenance
k Visual Management
l Poke Yoke
4 Pull Where You Cannot Flow 20
a Kanban
5 Strive For Perfection 20
a Kaizen
b 5S
E Classic Lean Case Studies 20
F Questions? 15

Product Note – Six Sigma Green Belt Training

Introduction

  1. Six Sigma is a measure of Quality of a process/product/service. If a process is performing at Six Sigma Quality, it means that there are only 0.0000034% defects in such process/product/service representing the absence of nearly all defects and thereby minimum possible variation in the process and ultimately greater positive customer experience.
  2. Six Sigma Quality is achieved through a Methodology called as DMAIC (Define, Measure, Analyze, Improve & Control) which is a data-driven, Statistics and Change Management oriented Process Re-Engineering technique that focusses on reducing the defects and variation in the process to ensure uniform customer experience.
  3. Six Sigma Green Belt Training is an in-depth classroom Programme that teaches DMAIC Methodology and its associated Tools and Techniques that will enable you to complete a Green Belt Project under expert guidance.

Applicability

  1. Six Sigma is predominantly a Process Re-engineering Methodology for the Manufacturing Sector.
  2. It is applied to problems with Unknown Causes with Complex Solutions. However, It is also extensively used in the Service industry.
  3. Eg: Improving the Mileage of a Passenger Car. Improving the Cab Occupancy in Employee Transport Facility.

Learning Objectives

  1. Understand thoroughly the DMAIC Methodology and its associated Steps and Tools
  2. In-depth understanding of what is Data, Its Analysis, and Interpretation.
  3. How to approach a Six Sigma Project and complete it in your work environment under expert guidance.

Who Should Attend

Assistant Managers & above in all departments including Operations & Support Functions

Pedagogy

Classroom Training

Duration

1600 Minutes

Difficulty

Intermediate

Learning Access
Certified/Accredited By

MAGE

Six Sigma Green Belt Training

Serial No Index Index Day
I Introduction To Six Sigma 150 1
1 What is Quality 1
2 What is Six Sigma 1
3 History of Six Sigma 1
4 Methodologies of Six Sigma & Use 1
4 Methodologies of Six Sigma & Use 1
5 Applicability of Six Sigma 1
1
6 Levels of Training 1
7 Six Sigma Organization 1
8 Roles In a Six Sigma Function 1
9 The Six Sigma Approach 1
10 Difference Between Lean & Six Sigma 1
11 The Transfer Function 1
12 Introduction To DMAIC 1
13 The 15 Steps 1
14 Green Belt, Black Belt & Master Black Belt Projects 1
II Define 120 1
A Identification of Project CTQ 1
1 Voice of the Customer 1
2 Interviews/Feedbacks/Surveys 1
B Project Charter 1
1 ARMI 1
2 In & Out 1
C Process Mapping 1
1 SIPOC 1
2 L1/L2/L3 1

Six Sigma Green Belt Training-1

III Measure 360 1
A Identify CTQ Characteristics 1
1 Quality Function Deployment 1
2 CTQ Drill Down Tree 1
B Define Performance Standards 1
1 Blue Print 1
C Measurement System Analysis (MSA) 1
1 What is Data? 1
2 Types of Data 1
3 Classification of Data 1
4 Measures of Central Tendency & Dispersion 1
5 Normality 1
6 Stability 1
7 Rational Sub Grouping 1
8 Sampling 1
9 Types of Bias 2
10 Sampling Strategies 2
11 Sampling for Various Types of Data 2
12 Data Collection Plan 2
13 Metrics of MSA 2
14 Repeatability & Reproducibility 2
15 Variable Gauge R & R 2
16 Attribute Gauge R & R 2
IV Analyse 300 2
A Baseline Process Performance 2
1 Process Capability 2
2 Product Capability 2
B Define Performance Objectives 2
2
1 Benchmarking 2
C Identify Variation Sources 2
1 Fishbone/Ishikawa 2

Six Sigma Green Belt Training-2

III Measure 360 1
D Basic Tools 2
1 Descriptive Statistics 2
2 Box Plots 2
2 Pareto 2
E Hypothesis Testing 2
1 Null & Alternate Hypothesis 2
2 Alpha & Beta Error 2
3 P Value 2
4 Regression 2
5 Anova 2
6 Homogeniety of Variance 2
7 Moods Median Test 2
8 Chi-Square Analysis 2
9 Logistic Regression 2
V Improve 180 3
A Identify Vital Few Variables & Their Relationships 3
1 Screening DOE 3
2 Fractional Factorial DOE 3
3 Full Factorial DOE 3
VI Control 180 3
A Set Operating Tolerances 3
1 Statistical Tolerancing 3
B Process Control 3
1 Statistical Process Control 3
2 FMEA 3
3 Standard Operating Procedures & Training 3
4 Project Closure & Quality Net Income 3
VII Questions? 15 3