Course Outline :

Course Outline:

Module-1

·       Concepts of Six Sigma, Six Sigma Infrastructure, building the Six Sigma

·       Infrastructure

·       What is Six Sigma?

·       Why Six Sigma?

·       The Six Sigma philosophy

·       The Change Imperative

·       Change agents and their effects on organizations

·       Implementing Six Sigma

·       Timetable

·       Infrastructure

·       Change agents compensation and retention

·       Six Sigma Goals and Metrics

·       Attributes of good metrics

·       Six Sigma versus traditional three sigma performance

·       The balanced scorecard

·       Measuring cases and effects

·       Information systems

·       The Six Sigma philosophy & Six Sigma deployment and management

·       Six Sigma communication plan

·       Six Sigma organizational roles and responsibilities

·       Selecting the “Belts”

·       Integrating Six Sigma and related initiative

Module-2

·       Elements of customer-driven organizations

·       Becoming a customer-and market-driven enterprise

·       Elements of the transformed organization

·       Surveys and focus groups

·       Strategies for communicating with customers and employees

·       Surveys

·       Focus groups

·       Other customer information systems

·       Calculating the value of retention of customers

·       Customer perspective for Six Sigma

·       Strategy development plan for Six Sigma

·       Information Six Sigma with other information systems technologies

·       OLAP, data mining and Six Sigma

Module-3

·       Process Map and learning perspective for Six Sigma

·       Strategy deployment plan for Six Sigma

·       Quality Function Deployment Diagram for Six Sigma(QFD)

·       Supplier Input Process Output to the Customer(SIPOC) Quality function deployment(QFD)

·       Data collection and review of customer expectations, needs, requirements and specification

·       The Six Sigma process enterprise

·       Examples of processes

·       The source of conflict

·       A resolution to the conflict

·       Process excellence

·       Using QFD to link Six Sigma projects to strategies

·       Using QFD to link Six Sigma projects to strategies

·       The strategy deployment matrix

·       Deploying differentiators to operations

·       Contents Deploying operations plans to projects

·       Linking customer demands to budgets

·       Structured decision- making

Module-4

·       Six Sigma Tools and Techniques, Introduction to DMAIC and Other

·       Improvement Models

·       DMAIC, DMADV and learning models

·       Design for Six Sigma project framework Design of Experiments ( DOE)

·       Terminology

·       Definitions

·       Learning models

·       PDCA Model

·       Dynamic models of learning and adaptation Voice OF Business

·       7M Tools for Six Sigma Activity Network Diagram Fish Bone Diagram, Flow Chart for Six Sigma, Pareto Analysis Cause and Diagram, Tree Diagram with Real Time Example.

Module-5

·       Check sheets

·       PDPC (Process Decision Program Chart) for check sheets

·       Process Map/Project Chart for Six Sigma

·       Voice of Customer (VOC) for Six Sigma Process check sheets

·       Defect check sheets

·       Stratified defect check sheets

·       Defect location check sheets

·       Application of 7M Tools Affinity diagrams

·       Tree diagrams

·       Process decision program charts

·       Matrix diagrams

·       Interrelationship digraphs

·       Prioritization matrices

·       Activity network diagram

·       Other continuous improvement tools

Module-6

·       Choosing the right projects

·       Customer value projects

·       Shareholder value projects

·       Other Six Sigma projects

·       Analyzing project candidates

·       Benefit-cost analysis

·       A system for assessing Six Sigma projects

·       Enumerative versus analytic statistical methods

·       Enumerative statistical methods

·       Assumptions and robustness of tests

·       Distributions

·       Probability distributions for Six Sigma

·       Statistical inference, Basic Principles of Measurement

·       Scales of measurement

·       Reliability and validity of data

·       Definitions

·       Overview of statistical methods

Module-7

·       Hypothesis testing/Type I and Type II error

·       Principles of statistical process control

·       Terms and concepts

·       Objectives and benefits

·       Common and special causes of variation

·       Measurement Systems Analysis

·       R&R studies for continuous data

·       Discrimination, stability, bias, repeatability, reproducibility and linearity

·       Gage R&R analysis using Minitab

·       Output

·       Linearity

·       Attribute measurement error analysis

Module-8

·       Operational Definitions

·       Example of attribute inspection error analysis

·       Respectability and pairwise reproducibility

·       Minitab attribute gage R&R example

·       The Analyze Phase

·       Knowledge Discovery

·       Knowledge discovery tools

·       Run charts

·       Descriptive statistics

·       Histograms

·       Exploratory data analysis

·       Establishing the process baseline

·       Describing the process baseline

Module-9

·       Statistical Process Control Techniques

·       Statistical process control (SPC)

·       Types of control charts

·       Average and range, average and sigma, control charts for individual measurements, control charts for average occurrence-per-unit, control charts for counts of occurrence-per unit

·       Short-run SPC

·       Control chart selection, rational subgroup sampling

·       Control charts interpretation

·       EWMA charts

·       SPC and automatic process control

·       Minitab example of EWMA

Module-10

·       Process Capability Analysis

·       Process capability analysis (PCA)

·       How to perform a process capability study

·       Statistical analysis of process capability data

·       Process capability indexes

·       Interpreting capability indexes

·       Example of capability analysis using normally distributed

·       Variables data

·       Estimating process yield

·       Rolled through put yield and sigma level

·       Normalized yield and sigma level, Statistical Analysis of Cause and Eject

·       Testing common assumptions

·       Continuous versus discrete data

·       Independence assumption

·       Equal Variance assumption

Module-11

·       Regression and Correlation analysis

·       Scatter plots

·       Correlation and regression

·       Analysis of categorical data

·       Chi-square, tables

·       Contents

·       Logistic regression binary logistic regression, ordinal logistic regression and nominal logistic regression

·       Non-parametric methods

·       Guidelines on when to use non-parametric tests

·       Minitab’s nonparametric tests

·       The Improve Phase

·       Managing Six Sigma Projects

·       Useful project management tools and techniques

·       Project planning

·       Project Charter

·       Work breakdown structures

·       Feedback loops

·       Performance measures

Module-12

·       Gantt charts

·       Typical DMAIC project tasks and responsibilities

·       PERT-CPM- type project management systems

·       Resources

·       Resource conflicts

·       Cost considerations in project scheduling

·       Relevant stakeholders

·       Budgeting

·       Project management implementation

·       Management support and organizational roadblocks

·       Short-term(tactical) plans

·        Cross- functional collaboration

·        Continuous review and enhancement of quality process

·       Documentation and procedures

Module-13

·       Risk Assessment

·       Reliability and safety analysis

·       Reliability analysis

·       Risk assessment tools

·       Fault free analysis

·       Safety analysis

·       Failure mode and eject analysis ( FMEA)

·       FMEA process

·       Statistical tolerancing

·       Assumptions of formula

·       Tolerance intervals

·       Design of Experiments (DOE)

·       Terminology

·       Definition

·       Power and sample size

·       Example

·       Design Characteristics

·       Types of design

·       One-factor

·       Examples of applying common DOE methods using software

Module-14

·       Two-way ANOVA with no replicates

·       Two-way ANOVA with replicates

·       Full and fractional factorial

·       Empirical model building and sequential learning

·       Phase 0: Getting your bearings

·       Phase I: The screening experiments

·       Phase II: Steepest ascent (descent)

·       Phase III: The factorial experiment

·       Phase IV: The composite design

·       Phase V: Robust product and process design

·       Data mining, artificial  neural networks and virtual process mapping

·       Example

Module-15

·       The Control Phase

·       Maintaining Control After the Project

·       Business process control planning

·       How will we maintain the gains made?

·       Tools and techniques useful for control planning

·       Using SPC for ongoing control

·       Process control planning for short and small runs

·       Strategies for short and small runs

·       Preparing the short run process control plain (PCP)

·       Process audit

·        Selecting process control elements

·       The single part process

·       Other elements of the process control plan

·       PRE- Control

·       Setting up PRE- Control

·       Using PRE- Control

Module-16

·       Design for Six Sigma (DFSS)

·       Preliminary steps

·       Define

·       Identify CTQs

·       Beyond customer requirements Identifying ” delighters”

·       Using AHP to determine the relative importance of the CTQs

·       Measure

·       Measurement plan

·       Analyze

·       Using Customer demands to make design decisions

·       Using weighted CTQs in Decision-making

·       Pugh concept selection method

·       Design

·       Predicting CTQ performance

·       Process simulation

·       Virtual DOE using simulation software