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Introduction to Lean Six Sigma
 
 
 

Course Outline
 

Day One

  1. Overview of Lean Thinking

    1. What is Lean Thinking?

    2. History

    3. Principles

      1. Specifying value

      2. Identifying the value stream

      3. Eliminating waste

      4. Improving Flow

      5. Implementing pull

      6. Perfection and continuous improvement

  2. Overview of Six Sigma

    1. What is Six Sigma?

    2. History

    3. Elements

      1. Measuring variation and defects

      2. Data-driven problem solving

      3. Culture

  3. Overview of Lean Six Sigma

    1. Role of Lean Thinking

    2. Role of Six Sigma

    3. Considerations

  4. Getting Started

    1. Selecting a project

    2. Establishing the project team

  5. The Lean Thinking Process

    1. Step 1: Specifying value

      1. Identifying customers

      2. Determining customer needs and expectations
Day Two

  1. The Lean Thinking Process (Continued)

    1. Step 2: Mapping the value stream

      1. Scope

      2. Identifying inputs and outputs

      3. Capturing the flow

        1. Primary path

        2. Alternate paths

        3. Storage and transportation

        4. Functional responsibilities

        5. Information flows

      4. Identifying and collecting data

        1. Setup times

        2. Processing times

        3. Storage times

        4. Transportation distances and times

      5. Assembling the value stream map

    2. Step 3: Eliminating waste

      1. Types of waste

      2. Identifying waste

      3. Pruning/revising the value stream

Day Three

  1. The Lean Thinking Process (Continued)

    1. Step 4: Improving flow

      1. Objectives

      2. Benefits

      3. Identifying roadblocks

      4. Removing roadblocks

    2. Step 5: Implementing pull

      1. Objectives

      2. Benefits

      3. Techniques

Day Four

  1. The Lean Thinking Process (Continued)

    1. Step 6: Perfection and continuous improvement

      1. Kaizen

    2. Selecting and implementing improvements

      1. A word about change management

  2. The Six Sigma DMAIC Process

    1. Define

      1. Objectives

      2. Project charter

      3. Customer requirements and critical to quality factors

      4. Process map

Day Five

  1. The Six Sigma DMAIC Process (Continued)

    1. Measure

      1. Objectives

      2. Tools and techniques

        1. CTQ tree

        2. Types of measures

        3. Stratification

        4. Sampling

        5. Data collection plan

        6. Performance baseline

    2. Analyze

      1. Objectives

      2. Tools and techniques

        1. Histogram

        2. Pareto chart

        3. Run chart

        4. Cause and effect (fishbone) diagram

        5. Relations diagram

        6. Failure modes and effects analysis (FMEA)

        7. Scatter diagram

Day Six

  1. The Six Sigma DMAIC Process (Continued)

    1. Improve

      1. Objectives

      2. Tools and techniques

        1. Tree diagram

        2. Impact/effort matrix

        3. Decision matrix

        4. Force field analysis

        5. Pilot testing

    2. Control

      1. Objectives

      2. Tools and techniques

        1. Process documentation

        2. Process metrics

        3. Process Monitoring

          1. Control charts

        4. Process management plan

  2. Putting It All Together
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