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SIX SIGMA DMAIC Through our approach to teaching Six Sigma,
we have helped numerous individuals and groups to master the skills necessary to efficiently monitor, improve, characterize,
and optimize their processes. We incorporate hands-on demonstrations with training aids such as the Statapult to enhance understanding
and to make learning fun. Our goal is to do more than teach SPC and DOE...it is to insure that our course participants enjoy
themselves and are able to put the concepts into action!
The following materials are provided to each workshop attendee:
Textbook
Participant Guide
Software
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
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