Lean Six Sigma – Green Belt- Course Contents

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1 Evolution of Quality
2 PDCA Procedure What TQM does 70/20/10
3 Quality, QA and Organizational Culture Performance: Outcome and Output
4 Outcome types Performance = Efficiency + Effectiveness
5 Performance (Outcome) monitored through KPIs KPIs Dashboard: Monitoring KPIs
6 TQM Phases; I, II and III Effectiveness of TQM
7 Fundamentals of LSS LSS Definition
8 LSS Project types: Production, transactional, Why LSS project fails
design
9 4 sigma and 6 sigma process – Real life LSS Methodology
10 DMAIC usage DMAIC Approach example
11 Y = f(x) formula Funnel effect : Logical problem solving
12 Types of problems – improvement areas – Optimize process flow through LSS
Quality and Efficiency
13 Waste – a hidden factory Waste types
TIMWOOD
14 Types of wastes Waste: Overproduction
15 Waste: waiting Waste: Transportation
16 Waste: Inventory Waste: Motion
17 Waste: Over processing Waste: Defects
18 DMAIC Tools DMAIC Tool
19 Six Sigma Program types, SS, LSS, DFSS LSS- Structure
20 LSS project based Hierarchy LSS Structure- Ex-Management, Champions,
Black Belts, Green Belts, Team members
21 Black and Green belt – Functions
22 Roles / Traits / Responsibilities – Champion
23 Roles / Traits / Responsibilities – Black belt
24 LSS Company
25 Define Phase Project Selection, Project Charter, Team
Formation, Process Mapping
26 Project Selection- What are projects
27 Six Sigma Metrics DPMO Vs Sigma Level (Score)
28 Cost of Poor Quality – Hidden Factory Categories of Cost of Poor Quality (COPQ)
29 Example of Quality Cost Trend Analysis
30 COPQ (Cost of Poor Quality) Vs Sigma Level
31 Two Basis of Selecting project: Quality and Waste
32 Project Selection
33 Specific candidate project Potential project selection
34 Project impact
35 Benefits Vs Effort of a project
36 Critical to Quality characteristics Detailed project selection criteria
37 Prioritizing projects Project Charter Management
38 Project Charter Business Case
39 Problem Statement Goal Statement
40 Primary and Secondary metrics Examples – charters
44 Project Management of LSS project LSS Team formation
45 Interdependent elements in Groups
46 Teams Vs Groups Stages of team development
47 Process mapping Simple and special flow diagram
48 What is process Examples of processes
49 Process, major process, sub process, activities, Supplier, customer, product, service
tasks business process, administrative business
process, key process
50 Process management system, Process owner, Process architecture
process member
51 Definition of a process Core and supportive processes
52 Symbols for process mapping Process mapping views
53 Process mapping levels Linear and cross functional (Swim lane)
maps
55 SIPOC Diagram for Quality related issues
58 Measure Phase
59 Descriptive study , data collection, data study,
findings
60 Descriptive statistics Purpose of basic statistics
61 Types of data: Attributes data , variable data Discrete variables
62 Continuous variables Scaled data: nominal, ordinal, interval, ratio
63 Nominal Scale Ordinal scale
64 Interval scale Ratio scale
65 Descriptive analysis of qualitative data Tabular methods: one way table, two way
table
66 Graphical methods Descriptive analysis of quantitative data
67 Measures of location- arithmatic mean Median
68 Mode Measures of variation: Range & IQR (Inter
quartile range)
69 Standard deviation Variance
70 Distribution shape: Skewness Distribution shape: Kurtosis
71 Measure of Xs and Ys Graphing
72 Data collection sheet for measurement
73 Pivot chart example
74 Histogram Histogram with normal curve
77 Boxplot
79 Interval plot
82 Moving average
85 Pareto Chart
86 80:20 rule
88 Process capability analysis
89 Normal distribution- normal curve
90 Normality test
91 Anderson- darling test for normality Probability plot
93 Within vs overall capability Process capability vs specifications
94 Process capability index Cp Process capability analysis
95 Cp vs Cpk
99 Sigma calculation 3 sigma vs 6 sigma
100 1.5 sigma shift theory Process shift
103 Rolled throughput yield RTY
104 DPU defects per unit Defects per opportunity, DPMO
105 CTQ (Critical to quality)
106 Defective and Defect Defect opportunity
108 Yield, RTY
110 Six Sigma Metrics-Defects and the Hidden factory RTY Vs Final test yield
111 Dissecting process capability
113 DPMO conversion chart Cost of poor quality, Cycle time
118 MSA Measurement
119 Reference value / Master value Measurement system
120 MSA 5M Purpose of MSA
121 Measurement variation- Repeatability, Bias and Linearity, stability
Reproducibility, Accuracy
122 Accuracy and Precision
123 Types of variation Accuracy and precision
124 Measurement system errors Measurement System Decision
125 Measurement system decisions Gage linearity, gage bias
130 Repeatability Reproducibility
131 Measurement system metrics % Contribution- gage R&R
133 % Tolerance
134 Method calculating gage error
135 MSA sample guidelines- sample selection Gage R&R with cross method
143 Attribute agreement analysis
144 Appraiser score %, score vs attribute, screen
effective score, vs attribute
151 Analysis Phase
152 Control Charts SPC Statistical process chart
153 Evolution of control charts SPC and SQC Control Chart Anatomy
154 Control and out of control Variability and Stability
155 Why use control charts
156 Western electric rules for control Nelson test for control
157 Purpose of SPC Common cause variation, special cause
variation
158 Common cause and Special Cause Juran’s Triology
159 Steps for constructing control charts
160 Y=F(x) Size of sub groups
161 Impact of variation, frequency of sampling
170 Pre-control charts, red zone, yellow zone, green
zone
171 Constructing control charts Types of control charts- attribute and
 variable data
172 SPC selection process Variable control chart selection
173 Type of chart- when u need it Data Sample size, frequency
174 Benefits of X bar and R Control Chart
176 Range chart
178 Constructing moving range chart (I-MR) Individual and moving range chart
184 Attribute control charts Attribute selection charts
185 Constructing p chart Steps for p-chart
190 Constructing np chart Steps for np chart
194 Constructing c chart Steps for c chart
199 Constructing u chart Steps for u chart
204 Analysis Phase
205 Project phases and deliverables Identifying and verifying causes
206 Basic displays, causes focused brainstorming Obvious solutions, hypothesis testing, cause
tools, why why analysis, cause and effect and effect test, design of experiment
diagram, C &E metrics
207 Why why analysis
210 Cause and effect analysis
211 Brainstorming
214 Cause and effect diagram
213 XY matrix
217 VSM value stream mapping
225 Hypothesis testing
226 Testing for hypothesis procedure, chance of error Statistical hypothesis
230 T-Test
235 Normality test
237 Test of equal variance (Bartlett’s test)
240 Paired T - test
246 ANOVA
250 Correlation
258 Regression
267 FMEA (Failure Mode Effect Analysis)
269 Risk Management steps
277 RPN Risk priority number
279 Improve phase
280 DOE Design of Experiment Project status review
281 Six sigma strategy diagram Experiment – factors noise response
282 Objectives Response, Factors, Level, Treatment, Noise
283 Principles of Experimental Design Replicate, Repeat, Block,
284 Randomization
285 Types of Experiments
288 2K factorial, 22 factorial
294 Factorial plots Factorial design
304 Lean tools for process improvement Waste types: Muda Muri Mura TIMWOOD
8th type is unutilized resources
305 Lean manufacturing Lean manufacturing elements
306 Lean Manufacturing Tools
307 Workplace improvement 5S zone layout, organogram, 6th s is safety,
308 5S 5s organogram
310 Fixed point photography
312 Seiri – Sort out
314 Classification- Stratification Management 5S Tag
315 RED tag AREA
316 Typical red tag Register
317 Seiton – Set in order
327 Seiso – Shine
330 Seiketso – standardization
333 Shitsuke- sustain
335 Hoshin Kanri
336 5S PDCA Cycle (Management Methodology,
337 Nemawashi (Tree from seed)
338 Lean Value stream mapping
339 Spaghetti diagram
340 Visual Management
341 Andons visual controls
342 TPM – total productive maintenance OEE – Overall equipment effectiveness
343 OEE, availability, performance efficiency formula Kaizen, Kaizen Blitz, Kaizen Events
344 Kaikaku Breakthrough Imprevement Jidoka
345 Poka Yoke
346 SMED Single Minute exchange of die Quick Time reduction for error removal
change over example formula one cars
347 One touch set up (Less than a Minute)
348 Standardized work (Time & motion study)
350 Takt time
353 Just in time JIT
354 Kanban
355 Supermarket Kanban
356 Heijunka
357 Cellular manufacturing for Heijunka
358 Control Phase
360 Control Phase steps
361 Defect control
362 5-6 sigma full automation
363 4-5s process interruption
364 3-5 sigma mistake proofing
365 Styles of mistake proofing Mistake proofing devices design
366 Types of mistake proof devices
367 Defect prevention culture and good control plans
369 Control Charts (process parameter monitoring) to SPC Statistical process control
evaluate the conditions for special cases –
abnormal or with high productivity
370 Control Chart Anatomy Nelson tests
374 Control chart construction
375 SPC selection process (Control chart selection)
382 Attribute control charts Data type
383