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Lean and Six Sigma have evolved in Toyota, Japan and Motorola, USA respectively. Lean has a reputation of making the organization to drive cost reduction through creating an organization wide war on waste. Lean makes the organization competitive in the long-term. On the other hand, Six Sigma proved itself as the most effective problem solving approach and delivers breakthrough results in the short-term.
An organization can gain both in short-term and long-term by combining the Lean as well as Six Sigma approaches. Lean Sigma program combines the best of American and Japanese quality management practices.
ISL-certified Lean Six Sigma Green Belts learn the six sigma problems solving methodology (DMAIC), the statistical tools and Lean tools. The focus is to master the application skills rather than learning the theoretical understanding. The program makes extensive use of MS-Excel for data analysis.
Learning Objectives
- To understand the philosophy of Six Sigma
- To learn DMAIC methodology and application of various statistical tools
- To be able to lead Six Sigma Green Belt projects.
- To understand the basic concepts, tools and practices of Lean
- To learn tactical skills for implementing lean at specific process.
- To be able to explain the lean concepts to the team
- To be able to apply lean principles to different process settings
Methodology
This training and certification is delivered completely online. The Learning Management System (LMS) provides following elements:
Multimedia lecture (Audio lectures with automatic slide transition)
Quiz, with correct answers and explanations for the wrong answers.
Discussion forum for engaging in dialogue with other participants.
Step-by-Step project guidance
Course Content
The course is based on Body-of-Knowledge of IQF, USA and SME, USA:
- Six Sigma Concept & Philosophy
- Six Sigma Concepts and Philosophy
- Six Sigma Deployment
- Metrics: DPU,DPMO, RTY
- Champion, Black Belt and Green Belts
- Selecting Projects
- Define and Measure Stage
- Define Stage: Creating Project Charter, Identifying Customers & Their Needs and Requirements, Creating SIPOC
- Measure Stage: Identifying CTQs, Selecting Sampling Strategy and Collect the data, Establish the Baseline Performance
- Basic Statistics: Concept of Variation, Data Types; Normal, Exponential, Binomial, Poisson distributions, Measures of central tendency - Mean, Median, Mode, Measures of Dispersion - Range, Standard deviation, Variance, Central Limit Theorem
- Visualization Techniques: Process Mapping, Quality Function Deployment (QFD)
- Measurement System Analysis: Types of errors in Measurement System, R&R for Variable measurement, R&R for Visual Inspection
- Analyze Stage
- Analysis Stage : Sources of variation, Identifying root cause and Validation
- Data Analysis: common and special causes of variation, Control charts, Xbar and Range Chart, Individual and Moving Range Chart, Histogram, p-chart, c-chart, Pareto analysis, Pre-control charts
- Process Capability: Cp, Cpk, Pp, Ppk
- Cause Analysis: Cause and Effect diagram, Why-Why analysis.
- Diagnostic Techniques: Multi-Vari chart, Paired comparison
- Improve Stage
- Improving Stage: Generating Potential Solutions, Select the Best One, Developing Mistake-Proof Measures, Process Optimization, Validating the Results
- Advanced Statistics: Sampling distribution, Estimation, Hypothesis Testing, ANOVA, Correlation and Regression
- Design of Experiments (DoE): Fractional Factorial designs, Full Factorial designs.
- Control Stage
- Control Stage: Defining the Process Control System, Modifying the Documentation System, Conducting Training, Institute the Process Audit System, Quantifying the Gains
- Control Plans
- Failure Modes and Effects Analysis (FMEA).
- Team Working
- Origin and Philosophy Lean
- Mass production vs Lean
- Muda, Mura, Muri
- Seven Types of Wastes
- Value-added Activity
- Lean Manufacturing House
- Lean thinking Mode
- Operational Stability
- Indicators of Stability
- Strategies for stability
- Standards and Visual Control
- 5S, Red-tagging, Spaghetti diagram
- TPM, Six Big losses, quasi-problems
- Standard Work
- Standardization – benefits, pre-requisites, people focus
- 3 elements of standard work
- Takt time, work sequence, in-process stock
- Charts for standardized work – production capacity chart, standardized work combination table, standardized work analysis chart, job element sheet
- Individual and overall efficiency, manpower reduction
- kaizen and layouts
- Just-in-Time
- Little’s law
- Push system, large lot production
- Pull system, basics of JIT
- Continuous Process Flow, one piece flow
- Push scheduling, Kanban, Pacemaker process,
- Six Kanban Rules, types of kanbans
- Conveyance, Hejunka, Changes in demand
- Types of pull – Type A, B and C
- Jidoka
- Autonomation
- Zero-quality control
- Types of Inspection – Judgment, Informative, Source, Vertical, horizontal
- Three aspects of Poka yoke – Actions, Paths and Methods of detection
- Andon
- Involvement
- Goal involvement
- Types of Kaizen teams – Kaizen Circle Activities, Practical Kaizen Training
- Roles, Responsibilities of members, facilitators, managers etc.
- Kaizen Leadership
- Suggestion scheme – measurement, motivation
- Problem Solving
- A3 Problem Solving
- Introduction
- Problem Situation
- Target
- Theme
- Cause Analysis
- Countermeasures
- Implementation
- Follow-up
- IQF Lean Six Sigma BoK
- Distributions
- Statistical Inference & ANOVA
- Measurement Assurance
- SPC
- Process Capability
- Regression
- Lean Metrics
- Inventory Theory
Certification Criteria
IQF-Lean Six Sigma Green Belt certification is awarded on completion of the following:
Complete 13 learning modules
Score 60% or more in quiz at the end of each learning module
Score 50% or more in IQF-Lean Six Sigma Green Belt exam
Complete one Lean Six Sigma Project (Optional)
Registration
Register online at www.isl.co.in and pay Fee Rs 29,214/- (for students in India) and Rs 47,740/- (for students outside India) through Net Banking,UPI, Demand Draft or Cheque (in favour of Institute of Sigma Learning Pvt. Ltd, Hyderabad). You will receive the course material within 10 working days.
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