Lean Process and Six Sigma

  • Training Time: 2 Days,  9:00 am to 5:00 pm
  • Inclusion: Participants Manual and Certificate of Completion

During the last couple of decades, small, mid-sized and Fortune 500 companies have embraced Six Sigma to generate more profit and greater savings. So what is Six Sigma?

Six Sigma is a data-driven approach for eliminating defects and waste in any business process. You can compare Six Sigma with turning your water faucet and experiencing the flow of clean, clear water. Reliable systems are in place to purify, treat, and pressure the water through the faucet. That is what Six Sigma does to business: it treats the processes in business so that they deliver their intended result.

What is “Sigma”? The word is a statistical term that measures how far a given process deviates from perfection. Sigma is a way to measure quality and performance. The central idea behind Six Sigma is that if you can measure how many “defects” you have in a process, you can systematically figure out how to eliminate them and get as close to “zero defects” as possible. This workshop will give participants an overview of the Six Sigma methodology, and some of the tools required to deploy Six Sigma in their own organizations.

Learning Points
  • Develop a 360 degree view of Six Sigma and how it can be implemented in any organization.
  • Identify the fundamentals of lean manufacturing, lean enterprise, and lean principles.
  • Describe the key dimensions of quality – product features and freedom from deficiencies
  • Develop attributes and value according to the Kano Model
  • Understand how products and services that have the right features and are free from deficiencies can promote customer satisfaction and attract and retain new customers.
  • Describe what is required to regulate a process
  • Give examples of how poor quality affects operating expenses in the areas of appraisal, inspection costs, internal failure costs, and external failure costs
  • Using basic techniques such as DMAIC and how to identify Six Sigma Projects
  • Use specific criteria to evaluate a project
  • Discover root causes of a problem
  • Design and install new controls to hold the gains and to prevent the problem from returning.
  • Gain an integrated view of anger management and how it can be best practiced.
Course Outline

Lean Process and Six Sigma – Module 1
Getting Started

  • Introduction to the Workshop
  • Workshop Objectives
  • Pre-Assignment Review

Lean Process and Six Sigma – Module 2
Understanding Lean

  • About Six Sigma
  • About Lean
  • History behind Lean
  • Toyota Production Systems
  • The Toyota Precepts

Lean Process and Six Sigma – Module 3
Liker’s Toyota Way

  • Philosophy
  • Process
  • People and Partners
  • Problem Solving

Lean Process and Six Sigma – Module 4
The TPS House

  • The Goals of TPS
  • The First Pillar:     Just in Time (JIT)
  • The Second Pillar: Jidoka (Error-Free Production)
  • Kaizen (Continuous Improvement)
  • The Foundation of the House

Lean Process and Six Sigma – Module 5
The Five Principles of Lean Business

  • Value
  • Value Stream
  • Flow
  • Pull
  • Seek Perfection

Lean Process and Six Sigma – Module 6
The 1st Improvement Concept (Value)

  • Basic Characteristics
  • Satisfiers
  • Delighters
  • Applying the Kano Model

Lean Process and Six Sigma – Module 7
The 2nd Improvement Concept (Waste)

  • Muda
  • Mura
  • Muri
  • The New Wastes

Lean Process and Six Sigma – Module 8
The 3rd Improvement Concept (Variation)

  • Common Cause
  • Special Cause
  • Tampering
  • Structural

Lean Process and Six Sigma – Module 9
The 4th Improvement Concept (Complexity)

  • What is Complexity?
  • What Causes Complexity?
  • How to Simplify?
  • Motivation
  • Overcoming Limitations

Lean Process and Six Sigma – Module 10
5th Improvement Concept (Continuous Improvement)

  • The PDSA Cycle (Plan, Do, Study, Act)
  • The DMAIC Method

Lean Process and Six Sigma – Module 11
The Improvement Toolkit

  • Gemba
  • Gendchi Genbutsu
  • Womack’s Principle
  • Kaizen
  • A Roadmap for Implementation

Lean Process and Six Sigma – Module 12
Wrapping it up

  • Words from the Wise
You Can Expect...
  • To learn basic goals of lean manufacturing
  • To understand the “Toyota Culture” and use it as take-off board
  • To have a good understanding of Lean Process and Six Sigma from usability standpoint
You Need This If...
  • You want to align your company to the Lean Process and Six Sigma values
  • You want all teams in your company to have a common vision and process
This Is About...
  • Bringing problems to the surface, and redesigning work processes to eliminate waste.
  • Having a vision of generating value and getting things right the first
  • Standardizing tasks and processes, and working with reliability
  • Leadership philosophy and with it, leadership driven-actions