Module I: Introduction to Six Sigma

Chapter 1: Understanding Basic Concepts and Structured Problem Solving

• Understanding Quality, Customer, Variation, Measuring variationVoice of Customer (VOC) and Critical to Quality (CTQ)

• Understanding Structured Problem solving: How do we solve problems in daily life and how it is different from Structured problem solving

Chapter 2: Various Common Problem Solving Methodologies (used for routine problem-solving)

• Understanding Various common Problem-Solving Methodologies which we use to solve daily routine problems like Just Do it, Suggestion Scheme, Kaizen, PDCA etc.

Chapter 3: What is Six Sigma?

• Data-Driven Decision-Making and how it makes the Difference?

• Understanding and Defining Six Sigma

• Different levels of Lean Six Sigma Certifications

• History of Six Sigma

• Common Six Sigma Principles

• Challenges of Six Sigma

Chapter 4: Six Sigma History and Application

• Origin of Six Sigma

• Motorola’s Focus on Defects

• Adaptation of Six Sigma by different companies

  
  
  
  

Chapter 5: Understanding Six Sigma DMAIC

• Basic understanding of Six Sigma (DMAIC) through a role play

• When to use Six Sigma

Chapter 6: 8 Types of Wastes

• 7 +1 Types of Waste (Muda)

Chapter 7: Approaching the Problem

• Understanding y= f(x)

• 5 Why approach

Module II: Selecting the Right Project and Methodology

Chapter 8: Project Selection

• Various Sources of Projects

• Selecting the right project

Chapter 9: Project Governance and Team Structure

• Project governance

• Project team, Various roles and their responsibilities

• How to select a right team

Chapter 10: Understanding DMAIC and DMADV - Overview

• Understanding the application of DMAIC and DMADV

• Define

• Measure

• Analyze

• Improve

• ControlDesignVerify

Chapter 11: Selecting the Right Methodology

• Just Do it

• Kaizen

• Kaizen Event

• PDCA

• Six Sigma DMAIC

• Six Sigma DMADV

Module III: Understanding DMAIC Phases in Detail

Chapter 12: Define Phase

• Business Case

• Understanding Project Charter

• Learning various components of Project charter

• - Problem statement

• - Goal Statement and Goal Setting

• -Problem Definition Tree

• - Project Scoping

• - Project Team

• - Project Planning

• - Financial Benefits

• Define Phase Tollgate review

Chapter 13: Measure Phase

• Understanding Process Mapping

• Overview of Value Stream Mapping (VSM)

• Quick Wins

• Understanding CTQ and Project Metric

• Operational Definition

• Understanding various Types of data

• Sampling techniques

• Data Collection Plan and Checklist

• Basic Statistics

• Understanding Normal Distribution

• Understanding Minitab

• Various types of Graphical analysis using Minitab / Excel

• Measurement System Analysis

• - Attribute MSA

• - GRR

• Process Stability

• Various Metrics for Process Performance

• - DPU, DPO and DPMO

• - CpK

• - Sigma Level

• - Yield

• Calculating Baseline Performance

• Measure phase Tollgate review

Chapter 14: Analyze Phase

• Brainstorming: Cause & Effect Diagram

• Failure Mode & Effect Analysis

• Pareto Chart

• Frequency Relevancy Analysis

• VA NVA Analysis

• Hypothesis Testing

• Various Types of Statistical Analysis

• - Test of the mean ( 1 sample t-test, 2 sample t-test, Paired t-test, ANOVA)

• - Test of Variance ( 1 sample Standard deviation, 2-sample standard deviation, Standard Deviation test)

• - Correlation and Regression

• - 1 sample % Defective, 2 Sample % Defective, Chi-Square test for Association

• Gap Analysis

• Analyze Phase Toll Gate

Chapter 15: Improve Phase

• Various solution-generation techniques

• Kaizen Events

• Multi-voting

• Soultion Selection Matrix

• Cost Benefit Analysis

• Pilot testing

• Planning and Full-scale Implementation

• Statistical validation of Improvements in outcome

• Improve Phase Toll Gate

Chapter 16: Control Phase

• Need for Control

• Various Control Mechanisms

• Poka Yoke

• Statistical Process Control / Control Charts

• - IMR Chart

• - X Bar R chart

• - X Bar S Chart

• - P chart

• - U chart

• Creating a Control Plan

• Visual Management

• Revise FMEA

• Team celebration and reflections

• Control phase Toll Gate Review

Chapter 17: Sample Project Walk Through

• Sample Project Walk Through

• Reflections

Module IV: Advance Project Selection and Advanced DMAIC

Chapter 18: Capturing VOC

• VOC Capturing methods

• KANO Analysis

• Challenges in capturing VOC

Chapter 19: Advanced techniques of Projects Selection and Prioritization

• Understanding COQ, COGQ and COPQ

• Quality Function Deployment (QFD)

• Balanced Scorecard

• CTQ Drill Down Technique

• Goal Mean Diagram

• Project Prioritization

Chapter 20: Advanced Define Tools

• Teaming module

• Conflict Management

• Project Management - Activity on Arrow Diagram

• Critical Path Method

• Calculating Critical path

• Advantages of using Critical Path

• Change Management

• Change Management Strategies

Chapter 21: Advanced Measure Tools

• Different types of Process Map and application

• Value Stream Mapping

• Case Study using VSM

• Continuous Flow and Batch Flow

• Benefits of Continuous Flow

• Common mistakes while considering Non-Normal Data for Non-Normal data

• Handling Non Noraml Data

• Box-Cox Transformation

• Johnson Transformation

• Baseline Calculation for Non Normal Data

Chapter 22: Advanced Analyze Tools

• Data Stratification

• Multi-variate Analysis

• Errors in Decision Making

• Understanding Type I and Type II Errors in Detail

• Deciding what value of Type I error is suitable in a situation

• Sample Size calculation for various statistical tests

• Hypothesis Testing: Nonparametric Tests

• - 1-Sample Sign Test

• - Mann-Whitney Test

• - Kruskal-Wallis Test

• - Moods Median Test

• Multiple Linear Regression

• Logistics Regression

• Fractional Factorial Design of Experiments

Chapter 23: Advanced Improve Tools

• SCAMPER

• Mind Mapping

• Understanding Experimentation - need of doing experiments

• Understanding OFAT

• Understanding Factorial experimentation

• Understanding the Design of Experiments

• Full factorial and Fractional Factorial designs

• Benefits of Full Factorial and Fractional Factorial Designs

• Step by Step Learning of doing DOE using Minitab

• Understanding Main Effect and Interaction Effect

• Understanding the interpretation f DOE outcome

• Optimizing the Model

• Practising case studies of DOE

• Push and Pull

• SMED

• PUGH Matrix

• Force Field Analysis

Chapter 24: Advanced Control Tools

• Visual Management

• TPM

Chapter 25: Examination details

• Details about the examination

• Exam Pattern

• Dos & Don'ts

• Sample Questions for Practice