Lean Sigma

Program Description

The Lean Sigma program will endow the participant with the knowledge and skills necessary for understanding and applying the basic concepts, tools, procedures, practices, and methods associated with Six Sigma and the general field of process improvement. In addition, the participant will glean the time-proven knowledge, methods and tools associated with the best practices of a modern lean enterprise. The participant will learn how to solve on-going operational problems and discover how to enhance or otherwise streamline daily operations. Of course, this goal is accomplished by the application of lean manufacturing principles such as mistake-proofing, pull systems and basic shop-floor improvement practices, just to mention a few. Of interest, the participant will learn how to apply specific tools to a wide range of commercial as well as industrial applications. Naturally, the lean tools and methods presented in this course can serve as an excellent entry point for initiating the deployment of Six Sigma.

In other words, the practices associated with a lean production system can be used to solve many line-of-sight problems and remove the low hanging fruit; thereby, clearing a path for the full-scale installation and utilization of Six Sigma practices. This independent yet integrated approach is often called Lean Sigma and represents a viable solution for many organizations. In this sense, the Lean Sigma program is an offering that is good for everyone. It can increase the power of virtually anyone working in an industrial or commercial enterprise that is striving to realize a never-ending stream of continuous improvements. Thus, the participant will discover how a strong, positive contribution can be realized using the concepts and tools provided in this program of study.

Reinforcement of major concepts, techniques, and application is realized through exercises, scenarios, and focused case studies. Through this training, the participant will gain tremendous insight into the logic and reasoning which underlies Six Sigma and the aims of breakthrough improvement. Total instructional time for this program is approximately 12 hours.

      Downloadable Program Syllabus

Breakthrough Vision

Content Overview - Understand the nature, purpose, and drivers of Six Sigma

Driving Need - Identify the needs that underlie a Six Sigma initiative

Customer Focus - Explain why focusing on the customer is essential to business success

Core Beliefs - Contrast the core beliefs of Six Sigma to conventional practices

Deterministic Reasoning - Describe a basic cause-and-effect relationship in terms of Y=f(X)

Leverage Principle - Relate the principle of leverage to an improvement project

Performance Breakthrough - Describe the underlying logic of the DMAIC improvement process

Business Principles

Quality Definition - Articulate the idea of quality in terms of value entitlement

Value Proposition - Define the primary components of value and their key elements

Process Management

Performance Yield - Explain why final yield is often higher than first-time yield

Hidden Processes - Describe the non-value added component of a process

Measurement Power - Describe the role of measurement in an improvement initiative

Performance Benchmarks - Explain how a benchmarking chart can be used to assess quality performance

Defect Opportunity - Understand the nature of a defect opportunity and its role in metrics reporting

Value Focus

Value Creation - Define the idea of value and explain how it can be created

Recognize Needs - Recognize the power of need fulfillment and how it links to value creation

Define Opportunities - Understand how to define opportunities that lead to the creation of value

Measure Conditions - Identify and evaluate the conditions that underlies improvement opportunity

Analyze Forces - Explain how the underlying forces are identified and leveraged to create beneficial change

Improve Settings - Establish optimal settings for each of the key forces that underpins beneficial change

Control Variations - Discuss how unwanted variations can mask the pathway to breakthrough

Standardize Factors - Understand the role and importance of standardized success factors

Integrate Lessons - Explain how key lessons learned can be merged into a set of best practices

Application Example - Understand how the breakthrough process can be applied to everyday life

Lean Practices

Lean Thinking - Comprehend the underlying logic of lean thinking

Constraint Theory - Explain how constraint theory is related to value creation

Continuous Flow - Describe the operational ideas that underpins continuous flow

Pull Systems - Contrast the operation of a push system to that of a pull system

Visual Factory - Explain the role of a visual factory during improvement efforts

Kanban System - Describe how a Kanban system can improve process cycle-time

PokaYoke System - Understand how PokaYoke systems can lead to quality improvement

6S System - Explain how the 6S system can contribute to process efficiency

SMED System - Define the basic elements of an SMED system

7W Approach - Describe how the 7W approach can be used to solve problems

6M Approach - Explain how the 6M approach is used to identify sources of causation

Quality Tools

Variable Classifications - Define the various types of variables commonly encountered during quality improvement

Measurement Scales - Describe each of the four primary scales of measure and their relative power

Problem Definition - Characterize the nature of a sound problem statement

Focused Brainstorming - Explain how focused brainstorming is used to facilitate improvement efforts

Process Mapping - Understand how to define the flow of a process and map its operations

SIPOC Diagram - Describe the nature and purpose of an SIPOC diagram

Force-Field Analysis - Utilize force field analysis to solve problems

Performance Sampling - Explain how to design and implement a sampling plan

Check Sheets - Understand how check sheets can be used for purposes of data collection

Analytical Charts - Identify the general range of analytical charts that can be used to assess performance

Pareto Charts - Explain how Pareto charts can be used to isolate improvement leverage

Run Charts - Utilize run charts to assess and characterize time-based process data

Correlation Charts - Utilize a correlation chart to illustrate the association between two variables

Frequency Tables - Explain how to construct and interpret a frequency table

Performance Histograms - Construct and interpret a histogram and describe several purposes

Control Charts - Explain the purpose of statistical process control charts and the logic of their operation