PSI ASSOCIATES

MATERIALS and SOFTWARE

PROCESS SOLUTIONS INTERNATIONAL uses only the best materials available. SIX SIGMA MATERIALS (DMAIC - DFSS) PSI has partnered with Air Academy Press for our Six Sigma DMAIC materials, including their fully integrated textbooks (Knowledge Based Management, Basic Statistics and Understanding Industrial Designed Experiments), Student Particpant's Guides, and software (SPC-XL, DOE PRO-XL, DFSS MASTER, MultiSim, and Knowledge Notebook), following the "Keep It Simple Statistically" (KISS) philosophy pioneered by Air Academy Associates. We use the materials as our foundation for your learning, and will customize the course to meet your specific requirements. A NOTE ON THE NEED FOR CANDIDATE MENTORING and COACHING Candidate Mentoring and Coaching by experienced Masters is critical to initial learning and project success. This simple fact has been proven time and again, yet many companies attempt to "save money" by eliminating candidate Mentoring and Coaching from their training agenda. +++++++++++++++++++++++++++++++++++++++++++++++++++++++++++ GREEN BELT / BLACK BELT COURSE OUTLINE (Green Belt Training consists of Weeks 1 and 2 only) Training participants must have defined their DMAIC projects prior to the first week of training. Training weeks are separated by three to four week periods for the candidates to apply their knowledge to the projects. Projects will be reviewed in class during weeks 2 thru 4. Mentoring and coaching on an individual basis will occur the second week after each training session. WEEK 1: Building a Six Sigma Culture Infrastructure Roles and responsibilities Six Sigma Project master strategy Six Sigma Implementation strategy What is Six Sigma Terminology IPO (Input Process Output) diagrams Graphical meaning of average and standard deviation Introduction to measures of quality (Cp, Cpk, sigma level, first pass yield, defects) Cost of Poor Quality Knowledge Based Management Strategy (role of questions, critical thinking) Prioritize, Characterize, Optimize, Realize (PCOR) strategy Variance reduction using PF/CE/CNX/SOP Statapult and Card Drop Exercise The What and Why of Total Quality Total Quality Principles Philosophy of KBM Relationship to Six Sigma Six Sigma Change Model Change Management The Role of Statistics in Process Improvement Applications of Statistics Philosophy of Quality and Taguchi’s Loss Function Terminology Metrics (developing and validating) Failure Mode and Effect Analysis (FMEA)/Mistake proofing IPO Matrix Practice with SPC XL Making Sense out of Data using Graphical and Measurement Tools Graphical analysis Pareto diagrams Histograms Run charts Scatter diagrams Numerical measures Cp, Cpk Dpu, dpmo Sigma level, sigma capability Correlation Practice with SPC XL Measurement System Analysis Importance of understanding the measurement process X-bar/R and ANOVA methods for continuous data Binary or inspection data Metrics Precision-to-Tolerance ratio (P/TOL) Precision-to-Total ratio (P/TOT) Resolution Graphical analysis Statapult Exercise Practice with SPC XL Building a Knowledge Notebook Six Sigma Project Work WEEK 2: Probability Distributions Normal, binomial, and Poisson distributions Real world applications and use for problem solving Practice with SPC XL Sampling Distribution and Confidence Intervals Why do we sample? Application of the Central Limit Theorem Meaning of Confidence Confidence intervals and Sample Size Calculations Continuous data (average) Binary data (proportion) Practice with SPC XL Hypothesis Testing with Rules of Thumb Understanding the null and alternative hypotheses Type I and type II errors Detecting significant shifts in the average (t test) Detecting significant shifts in the standard deviation (F test) Detecting significant shifts in a proportion (Z-test) Chi square Test for Independence (categorical data) Practical rules of thumb for significance Statapult Exercise Practice with SPC XL Process Control and Process Capability Philosophy, construction and interpretation of control charts Control chart selection X-bar/R, X-bar/s, IMR, p and c charts Exercises Practice with SPC XL Regression Analysis Philosophy and Terminology Interpretation of output Exercises Practice with SPC XL Six Sigma Project Reports (status updates) given by participants WEEK 3: Foundations and Overview of DOE Terminology Strategies (screening, modeling) Y-hat and s-hat models Exercise Practice with DOE KISS Introduction to Design and Analysis 12 step template for DOE graphical analysis of data using response surfaces, contour plots, interaction plots and marginal means plots statistical analysis of data examples and exercises practice with DOE KISS Rules of Thumb Selecting designs Determining sample size Testing for significance Interpreting computer output Regression Modeling in DOE Summary of two-level Designs Summary of three-level Designs Analysis and Case Study Examples Variance Reduction and Robust Design Taguchi’s inner/outer array Variance reduction using s-hat models Six Sigma Project Reports (status updates) given by participants WEEK 4: Special Topics in DOE tailored to participant project needs Workshop activities using Multisim process simulation software Introduction to Multiple Response Optimization Introduction to DOE Pro software Course Wrap-up Six Sigma Project Reports (status updates) given by participants

DESIGN FOR SIX SIGMA COURSE OUTLINE Introduction to DFSS Keeping Score Voice of the Customer Systems Engineering and Requirements Flowdown Transfer Function Design for Robust Performance Tolerance Allocation Design for Manufacturability Product Capability Prediction Test and Validate Design for Six Sigma: Prerequisites Participants are expected to have management sponsorship. Participants should bring a laptop computer to class with Excel 97 (or above) so that they can install the supplied software and practice using it during many in-class exercises. A basic working knowledge of Windows and Excel is crucial. In addition, participants should be familiar with SPC XL, DOE KISS, DOE PRO, and Multisim. Subjects that the participants need to be familiar with: Knowledge Based Management Strategy (Questions Managers Need to Ask and Answer) Variance Reduction Methods, to include: PF/CE/CNX/SOP S-hat Modeling Interaction and Contour Plots Process Capability Measures (dpu, yield, dpm, sigma capability, Cp, Cpk) Probability Distributions, to include: Normal Exponential Uniform Binomial Poisson Hypothesis Testing, to include: Understanding the null and alternative hypotheses Type I and Type II errors Risks of false detection and missed detection Statistical Process Control, to include: X-Bar – R Charts X-Bar – S Charts Individual Charts Run Charts Design of Experiments (DOE), to include: Both 2-level and 3-level designs Both screening and modeling designs Regression analysis using DOE KISS and Multisim Graphical analysis using response surfaces, contour plots, and interaction plots Y-hat and S-hat models Multiple response optimization using DOE PRO Rules of Thumb for design selection and sample size Measurement System Analysis (MSA), to include: Both the X-Bar – R and ANOVA methods for continuous data Binary or inspection data Knowledge of Precision-to-Tolerance (P/TOL), Precision-to-Total (P/TOT) ratios, resolution, and graphical analysis

SOFTWARE Extremely powerful, easy to work with and understand software that doesn't require a statistician to use, and doesn't require a huge investment to purchase. No more long hours trying to learn complicated software - so intuitive that you can use it within minutes, right out of the box! Call or email us to find out how you can "test drive" this software - See for yourself its power and ease-of-use. +++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++ SOFTWARE by: Digital Computations and Air Academy Associates SPC-XL - A complete SPC solution integrated into Microsoft Excel. Create Control Charts, Histograms, Pareto Charts, Summary Statistics, Process Capability (Ppk/Cpk, Pp/Cp) Scatter Plots, Measurement System Analysis / Gage R&R, FMEA and much more. DOE Pro-XL - The Ultimate in Design of Experiments packages. Two and three level, multiple response capability with advanced analysis and optimization features enables you to take control of your experiments, all from within Microsoft Excel. DFSS Master - Tools for the Design for Six Sigma practitioner. Features include Monte Carlo Simulation, Tolerance Allocation, Parameter Design, Design Scorecard, and more. MultiSim - A simulation package for teaching DOE. Users can create and analyze designs, and optimize processes. An excellent package for those who need to practice Design of Experiments. Knowledge Notebook - All the forms and templates necessary to keep track of your DMAIC / DMADV / IDOV projects. Provides standard format and common language for your project data and information. +++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++ SOFTWARE by: ProcessModel ProcessModel version 4.2.7 - This powerful software performs Process Flow and Value Stream Analysis simulations, allowing you to graphically create and improve your business processes on your computer. Simulate WIP, queue, input distributions - your entire process, as it is. Then create the future state process and run "what-if" simulations to achieve the smoothest operating and optimized processes without costly trial-and-error experimentation and guesswork. Not sure of the input distribution? No problem - ProcessModel will determine the distribution of your data so there is no guesswork here, either - this is s really nice feature!!

COPYRIGHTED TRAINING MATERIALS Our "Project Management for Process Improvement Projects" three day seminars and materials have been presented through the Extended Studies and Professional Development Departments of many top-rated colleges and universities, including: Pepperdine Graziadio School of Business and Management, University of Chicago, UC Berkeley, Rutgers, Towson, George Mason, Michigan State Eli Broad School of Business, San Diego State, and Colorado State.