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Monday
- Introduction: ISO 9000:2000, Six Sigma, EFQM
- Six sigma and Lean philosophy
- Methodology overview: DMAIC
- Implementation: key players and roles
- Define the opportunity:
- What is important?
- Project team: goals, objectives, scope,
business case
- Baseline analysis
- SMART problem statement
- The voice of the customer: translation into
process specifications
- Process mapping and flowcharting: SIPOC
- Value stream mapping group work using MS Excel
forms
Tuesday
Measure performance
- What to measure? Customer perspective, business results, process
metrics
- Common process metrics:
- Rolled Throughput Yield
- DPU, DPMO
- Inspection/ test: coverage and yield
- Takt time and cycle time
- Cost, dedications
- Customer satisfaction
- Data collection methodology
- Understanding variation: group exercise
- Run charts and histograms
- Process capability: Cp, Cpk, sigma capability
- Attributes and variables data
- Customer satisfaction and lead-time frequency
distributions
- Group work: identify process metrics using MS
Excel
- Measurement System Analysis (Gage R&R)
Wednesday
Analyze the opportunity
- What needs to be improved? Symptoms
- Root cause: Fishbone diagram. Group exercise
- Collect the data: Pareto Chart
- Scatter plot and correlation analysis
- Analyze the value stream map:
- Process inputs characterization
- Sources of defects, delays and variation
- Bottleneck identification
- Constraint management with MS Excel Solver: examples
- Corrective actions: 8 Discipline methodology
- Prevention: Failure Mode & Effects Analysis. Group work
Thursday
Improve performance
- Benchmarking similar processes
- Process documentation: procedures, work instructions
- Mistake Proofing: Poka-Yoke
- Bottleneck management
- Set-up time and lot size reduction
- Pull Vs Push logistics: Kanban simulation exercise
- Preventive maintenance
- Analysis of alternative solutions
- Throughput/ Work-In-Process/ Cycle time relationship
- Yield loss, capacity and variability bottlenecks
- Just-In-Time production. Impact of variability
- Process simulation exercise (MS Excel): real life optimization
- Capability improvement: Design of experiments
Friday
Control performance
- Process control plan and implementation
- Group work with MS Excel forms
- 5S: Workplace order and cleanness
- Statistical process control
- Attributes and variables control charts
- Western Electric rules: interpretation
- Discrimination, Repeatability, Reproducibility
- Real-time feedback to the operator for immediate action
- Out of control: Who does what?
Project implementation:
- Pilot solution
- Identify side effects
- Document process changes
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