This four week curriculum follows the DMAIC methodology (Define, Measure, Analyze, Improve, and Control). Both Lean and Six Sigma tools are fully integrated in each phase. The modules are packed with manufacturing, operations, and transactional/services examples. The course includes simulations and hands-on case studies for tool application, and concludes with a cumulative capstone exercise.
Introduction to Lean Six Sigma
Define Phase
- Introduction to Define and Gate Reviews
- The Project Charter
- Project and Change Management
- Multigenerational Project Planning
- Gathering Voice of the Customer
Measure Phase
- Introduction to Measure
- Document and Analyze the Process
- Cause and Effect Matrix
- Minitab Overview
- Introduction to Basic Statistics
- Data Collection
- Understanding Variation and Control Charts
- Measurement System Analysis (MSA)
- Process Capability
- Key Lean Concepts
- Transactional Lead Time Simulation
Analyze Phase
- Introduction to Analyze
- Root Cause ID and Validation
- FMEA
- Confidence Intervals
- Hypothesis Testing
- Means, Medians and Variance Tests (Including ANOVA and Non-Parametrics)
- Quick Improvement Methods
- Quick Wins and Kaizen
- 5S
- Process Flow Improvement
- Changeover Reduction
- Simple & Multiple Linear Regression
- Proportion and Chi Square Tests
- Multi-Vari Analysis
Improve Phase
- Introduction to Improve
- Core Simulation Round 1
- Solution Development
- Quick Improvement – CONWIP/Work Control Systems
- Core Simulation Round 2
- Quick Improvement - ABC Part Stratification
- Quick Improvement – TPM
- Replenishment Pull Systems
- Core Simulation Round 3
- Pre-DOE Exercise
- Introduction to Design of Experiments (DOE)
- Full Factorial DOE
- Fractional Factorial DOE
- DOE Planning
- DOE Catapult Simulation
- Implementation
Control Phase
- Introduction to Control
- Mistake Proofing
- Process Control Methods
- Visual Control Methods
- Extending the Improvements
- Project Close-Out
- Cumulative Case Study
- Review and Final Test
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