Lean Six Sigma

  1. The Six Sigma Framework
    1. Core Six Sigma Concepts
      1. Understanding Process Variation
        1. Common Cause Variation
          1. Natural Process Fluctuations
            1. System-Inherent Variation
            2. Special Cause Variation
              1. Assignable Causes
                1. Unusual Events
                2. Variation Reduction Strategies
                  1. Process Control
                    1. System Improvement
                  2. The Concept of a Defect
                    1. Defining Defects
                      1. Customer Requirements
                        1. Specification Limits
                        2. Defect Opportunities
                          1. Opportunity Identification
                            1. Counting Methods
                            2. Defect Classification
                              1. Critical Defects
                                1. Major Defects
                                  1. Minor Defects
                                2. Defects Per Million Opportunities (DPMO)
                                  1. Calculating DPMO
                                    1. Formula Application
                                      1. Data Requirements
                                      2. Interpreting Results
                                        1. Performance Benchmarking
                                          1. Improvement Targets
                                        2. Sigma Level
                                          1. Understanding Sigma Metrics
                                            1. Statistical Significance
                                              1. Process Capability
                                              2. Relating Sigma Level to Quality
                                                1. Quality Performance
                                                  1. Business Impact
                                                  2. Sigma Level Calculation
                                                    1. Conversion Tables
                                                      1. Statistical Methods
                                                    2. The Normal Distribution
                                                      1. Properties of Normal Distribution
                                                        1. Bell Curve Characteristics
                                                          1. Standard Deviation
                                                          2. Application in Six Sigma
                                                            1. Process Capability
                                                              1. Control Limits
                                                              2. Distribution Analysis
                                                                1. Normality Testing
                                                                  1. Data Transformation
                                                              3. The DMAIC Methodology
                                                                1. Define Phase
                                                                  1. Project Selection
                                                                    1. Selection Criteria
                                                                      1. Business Impact Assessment
                                                                        1. Resource Requirements
                                                                        2. Developing Project Charter
                                                                          1. Problem Statement
                                                                            1. Goal Statement
                                                                              1. Team Roles and Responsibilities
                                                                                1. Timeline and Milestones
                                                                                2. Defining Business Case
                                                                                  1. Financial Impact
                                                                                    1. Strategic Alignment
                                                                                      1. Risk Assessment
                                                                                      2. Understanding Voice of Customer (VOC)
                                                                                        1. Collecting Customer Feedback
                                                                                          1. Survey Methods
                                                                                            1. Interview Techniques
                                                                                              1. Kano Model
                                                                                                1. Basic Needs
                                                                                                  1. Performance Needs
                                                                                                    1. Excitement Needs
                                                                                                    2. Critical to Quality (CTQ) Trees
                                                                                                      1. Translating VOC to Requirements
                                                                                                        1. Specification Development
                                                                                                      2. High-Level Process Mapping
                                                                                                        1. SIPOC Diagram
                                                                                                          1. Suppliers
                                                                                                            1. Inputs
                                                                                                              1. Process
                                                                                                                1. Outputs
                                                                                                                  1. Customers
                                                                                                                  2. Process Boundaries
                                                                                                                    1. Key Stakeholders
                                                                                                                  3. Measure Phase
                                                                                                                    1. Developing Data Collection Plan
                                                                                                                      1. Identifying Data Sources
                                                                                                                        1. Sampling Methods
                                                                                                                          1. Data Collection Forms
                                                                                                                          2. Understanding Data Types
                                                                                                                            1. Continuous Data
                                                                                                                              1. Measurement Scales
                                                                                                                                1. Precision Requirements
                                                                                                                                2. Discrete Data
                                                                                                                                  1. Counting Methods
                                                                                                                                    1. Attribute Data
                                                                                                                                  2. Measurement System Analysis (MSA)
                                                                                                                                    1. Gage R&R Studies
                                                                                                                                      1. Repeatability Analysis
                                                                                                                                        1. Reproducibility Analysis
                                                                                                                                        2. Accuracy and Precision
                                                                                                                                          1. Bias Assessment
                                                                                                                                            1. Linearity Studies
                                                                                                                                            2. Attribute Agreement Analysis
                                                                                                                                              1. Operator Consistency
                                                                                                                                                1. Standard Comparison
                                                                                                                                              2. Establishing Process Baseline
                                                                                                                                                1. Current Performance Metrics
                                                                                                                                                  1. Baseline Data Analysis
                                                                                                                                                  2. Basic Statistical Concepts
                                                                                                                                                    1. Measures of Central Tendency
                                                                                                                                                      1. Mean
                                                                                                                                                        1. Median
                                                                                                                                                          1. Mode
                                                                                                                                                          2. Measures of Variation
                                                                                                                                                            1. Range
                                                                                                                                                              1. Variance
                                                                                                                                                                1. Standard Deviation
                                                                                                                                                                2. Data Distribution Shapes
                                                                                                                                                                  1. Skewness
                                                                                                                                                                    1. Kurtosis
                                                                                                                                                                  2. Process Capability Analysis
                                                                                                                                                                    1. Short-Term Capability
                                                                                                                                                                      1. Cp (Process Capability)
                                                                                                                                                                        1. Cpk (Process Capability Index)
                                                                                                                                                                        2. Long-Term Capability
                                                                                                                                                                          1. Pp (Process Performance)
                                                                                                                                                                            1. Ppk (Process Performance Index)
                                                                                                                                                                            2. Capability Interpretation
                                                                                                                                                                              1. Specification Limits
                                                                                                                                                                                1. Process Centering
                                                                                                                                                                            3. Analyze Phase
                                                                                                                                                                              1. Detailed Process Analysis
                                                                                                                                                                                1. Process Mapping
                                                                                                                                                                                  1. Detailed Flow Charts
                                                                                                                                                                                    1. Swim Lane Diagrams
                                                                                                                                                                                    2. Identifying Bottlenecks
                                                                                                                                                                                      1. Capacity Analysis
                                                                                                                                                                                        1. Constraint Theory
                                                                                                                                                                                      2. Root Cause Analysis (RCA) Tools
                                                                                                                                                                                        1. The 5 Whys
                                                                                                                                                                                          1. Iterative Questioning
                                                                                                                                                                                            1. Cause Chain Analysis
                                                                                                                                                                                            2. Fishbone Diagram (Ishikawa Diagram)
                                                                                                                                                                                              1. Cause Categories
                                                                                                                                                                                                1. Man
                                                                                                                                                                                                  1. Machine
                                                                                                                                                                                                    1. Method
                                                                                                                                                                                                      1. Material
                                                                                                                                                                                                        1. Measurement
                                                                                                                                                                                                          1. Environment
                                                                                                                                                                                                        2. Pareto Charts
                                                                                                                                                                                                          1. 80/20 Rule
                                                                                                                                                                                                            1. Prioritizing Issues
                                                                                                                                                                                                          2. Graphical Analysis Tools
                                                                                                                                                                                                            1. Histograms
                                                                                                                                                                                                              1. Frequency Distributions
                                                                                                                                                                                                                1. Data Patterns
                                                                                                                                                                                                                2. Box Plots
                                                                                                                                                                                                                  1. Quartile Analysis
                                                                                                                                                                                                                    1. Outlier Identification
                                                                                                                                                                                                                    2. Scatter Plots
                                                                                                                                                                                                                      1. Correlation Analysis
                                                                                                                                                                                                                        1. Relationship Patterns
                                                                                                                                                                                                                        2. Run Charts
                                                                                                                                                                                                                          1. Trend Analysis
                                                                                                                                                                                                                            1. Time Series Data
                                                                                                                                                                                                                          2. Hypothesis Testing
                                                                                                                                                                                                                            1. Introduction to Hypothesis Testing
                                                                                                                                                                                                                              1. Null Hypothesis
                                                                                                                                                                                                                                1. Alternative Hypothesis
                                                                                                                                                                                                                                  1. Type I and Type II Errors
                                                                                                                                                                                                                                  2. T-Tests
                                                                                                                                                                                                                                    1. One-Sample T-Test
                                                                                                                                                                                                                                      1. Two-Sample T-Test
                                                                                                                                                                                                                                        1. Paired T-Test
                                                                                                                                                                                                                                        2. ANOVA (Analysis of Variance)
                                                                                                                                                                                                                                          1. One-Way ANOVA
                                                                                                                                                                                                                                            1. Two-Way ANOVA
                                                                                                                                                                                                                                              1. Multiple Comparisons
                                                                                                                                                                                                                                              2. Chi-Square Test
                                                                                                                                                                                                                                                1. Goodness of Fit
                                                                                                                                                                                                                                                  1. Test of Independence
                                                                                                                                                                                                                                                  2. Non-Parametric Tests
                                                                                                                                                                                                                                                    1. Mann-Whitney Test
                                                                                                                                                                                                                                                      1. Kruskal-Wallis Test
                                                                                                                                                                                                                                                    2. Correlation and Regression Analysis
                                                                                                                                                                                                                                                      1. Correlation Coefficients
                                                                                                                                                                                                                                                        1. Pearson Correlation
                                                                                                                                                                                                                                                          1. Spearman Correlation
                                                                                                                                                                                                                                                          2. Simple Linear Regression
                                                                                                                                                                                                                                                            1. Regression Equation
                                                                                                                                                                                                                                                              1. R-Squared Analysis
                                                                                                                                                                                                                                                              2. Multiple Regression
                                                                                                                                                                                                                                                                1. Model Building
                                                                                                                                                                                                                                                                  1. Variable Selection
                                                                                                                                                                                                                                                              3. Improve Phase
                                                                                                                                                                                                                                                                1. Brainstorming and Generating Solutions
                                                                                                                                                                                                                                                                  1. Creative Problem Solving Techniques
                                                                                                                                                                                                                                                                    1. Brainstorming Sessions
                                                                                                                                                                                                                                                                      1. Mind Mapping
                                                                                                                                                                                                                                                                      2. Solution Categories
                                                                                                                                                                                                                                                                        1. Process Changes
                                                                                                                                                                                                                                                                          1. Technology Solutions
                                                                                                                                                                                                                                                                            1. Training Interventions
                                                                                                                                                                                                                                                                          2. Solution Selection and Prioritization
                                                                                                                                                                                                                                                                            1. Decision Matrices
                                                                                                                                                                                                                                                                              1. Criteria Weighting
                                                                                                                                                                                                                                                                                1. Solution Scoring
                                                                                                                                                                                                                                                                                2. Cost-Benefit Analysis
                                                                                                                                                                                                                                                                                  1. Implementation Costs
                                                                                                                                                                                                                                                                                    1. Expected Benefits
                                                                                                                                                                                                                                                                                    2. Risk Assessment
                                                                                                                                                                                                                                                                                      1. Implementation Risks
                                                                                                                                                                                                                                                                                        1. Mitigation Strategies
                                                                                                                                                                                                                                                                                      2. Failure Modes and Effects Analysis (FMEA)
                                                                                                                                                                                                                                                                                        1. Identifying Potential Failures
                                                                                                                                                                                                                                                                                          1. Failure Modes
                                                                                                                                                                                                                                                                                            1. Failure Effects
                                                                                                                                                                                                                                                                                            2. Risk Assessment
                                                                                                                                                                                                                                                                                              1. Severity Ratings
                                                                                                                                                                                                                                                                                                1. Occurrence Ratings
                                                                                                                                                                                                                                                                                                  1. Detection Ratings
                                                                                                                                                                                                                                                                                                  2. Risk Priority Number (RPN)
                                                                                                                                                                                                                                                                                                    1. Calculation Method
                                                                                                                                                                                                                                                                                                      1. Prioritization
                                                                                                                                                                                                                                                                                                    2. Design of Experiments (DOE)
                                                                                                                                                                                                                                                                                                      1. Experimental Design Principles
                                                                                                                                                                                                                                                                                                        1. Factors and Responses
                                                                                                                                                                                                                                                                                                          1. Randomization
                                                                                                                                                                                                                                                                                                          2. Full Factorial Designs
                                                                                                                                                                                                                                                                                                            1. Two-Level Designs
                                                                                                                                                                                                                                                                                                              1. Analysis Methods
                                                                                                                                                                                                                                                                                                              2. Fractional Factorial Designs
                                                                                                                                                                                                                                                                                                                1. Screening Experiments
                                                                                                                                                                                                                                                                                                                  1. Resolution Concepts
                                                                                                                                                                                                                                                                                                                2. Piloting Solutions
                                                                                                                                                                                                                                                                                                                  1. Pilot Planning
                                                                                                                                                                                                                                                                                                                    1. Scope Definition
                                                                                                                                                                                                                                                                                                                      1. Success Criteria
                                                                                                                                                                                                                                                                                                                      2. Testing on Small Scale
                                                                                                                                                                                                                                                                                                                        1. Controlled Environment
                                                                                                                                                                                                                                                                                                                          1. Data Collection
                                                                                                                                                                                                                                                                                                                          2. Gathering Feedback
                                                                                                                                                                                                                                                                                                                            1. Stakeholder Input
                                                                                                                                                                                                                                                                                                                              1. Performance Measurement
                                                                                                                                                                                                                                                                                                                            2. Planning for Implementation
                                                                                                                                                                                                                                                                                                                              1. Implementation Strategy
                                                                                                                                                                                                                                                                                                                                1. Rollout Plan
                                                                                                                                                                                                                                                                                                                                  1. Resource Requirements
                                                                                                                                                                                                                                                                                                                                  2. Change Management
                                                                                                                                                                                                                                                                                                                                    1. Communication Plan
                                                                                                                                                                                                                                                                                                                                      1. Training Requirements
                                                                                                                                                                                                                                                                                                                                        1. Resistance Management
                                                                                                                                                                                                                                                                                                                                    2. Control Phase
                                                                                                                                                                                                                                                                                                                                      1. Developing Control Plan
                                                                                                                                                                                                                                                                                                                                        1. Monitoring Key Metrics
                                                                                                                                                                                                                                                                                                                                          1. Critical Parameters
                                                                                                                                                                                                                                                                                                                                            1. Measurement Frequency
                                                                                                                                                                                                                                                                                                                                            2. Response Plans
                                                                                                                                                                                                                                                                                                                                              1. Action Triggers
                                                                                                                                                                                                                                                                                                                                                1. Corrective Actions
                                                                                                                                                                                                                                                                                                                                              2. Statistical Process Control (SPC)
                                                                                                                                                                                                                                                                                                                                                1. Control Charts
                                                                                                                                                                                                                                                                                                                                                  1. X-bar and R Charts
                                                                                                                                                                                                                                                                                                                                                    1. Individual and Moving Range Charts
                                                                                                                                                                                                                                                                                                                                                      1. p-Charts
                                                                                                                                                                                                                                                                                                                                                        1. c-Charts
                                                                                                                                                                                                                                                                                                                                                          1. u-Charts
                                                                                                                                                                                                                                                                                                                                                          2. Control Chart Interpretation
                                                                                                                                                                                                                                                                                                                                                            1. Control Limits
                                                                                                                                                                                                                                                                                                                                                              1. Out-of-Control Signals
                                                                                                                                                                                                                                                                                                                                                                1. Trend Analysis
                                                                                                                                                                                                                                                                                                                                                                2. Control Chart Implementation
                                                                                                                                                                                                                                                                                                                                                                  1. Chart Selection
                                                                                                                                                                                                                                                                                                                                                                    1. Sampling Strategy
                                                                                                                                                                                                                                                                                                                                                                  2. Standardizing Processes
                                                                                                                                                                                                                                                                                                                                                                    1. Standard Operating Procedures (SOPs)
                                                                                                                                                                                                                                                                                                                                                                      1. Documentation Requirements
                                                                                                                                                                                                                                                                                                                                                                        1. Process Steps
                                                                                                                                                                                                                                                                                                                                                                        2. Work Instructions
                                                                                                                                                                                                                                                                                                                                                                          1. Detailed Procedures
                                                                                                                                                                                                                                                                                                                                                                            1. Visual Aids
                                                                                                                                                                                                                                                                                                                                                                            2. Training and Certification
                                                                                                                                                                                                                                                                                                                                                                              1. Competency Requirements
                                                                                                                                                                                                                                                                                                                                                                                1. Skill Verification
                                                                                                                                                                                                                                                                                                                                                                              2. Documenting Results and Lessons Learned
                                                                                                                                                                                                                                                                                                                                                                                1. Project Documentation
                                                                                                                                                                                                                                                                                                                                                                                  1. Final Report
                                                                                                                                                                                                                                                                                                                                                                                    1. Data Analysis
                                                                                                                                                                                                                                                                                                                                                                                    2. Knowledge Transfer
                                                                                                                                                                                                                                                                                                                                                                                      1. Best Practices
                                                                                                                                                                                                                                                                                                                                                                                        1. Lessons Learned
                                                                                                                                                                                                                                                                                                                                                                                        2. Continuous Improvement Opportunities
                                                                                                                                                                                                                                                                                                                                                                                          1. Future Projects
                                                                                                                                                                                                                                                                                                                                                                                            1. Process Monitoring
                                                                                                                                                                                                                                                                                                                                                                                          2. Project Closure and Handover
                                                                                                                                                                                                                                                                                                                                                                                            1. Final Reporting
                                                                                                                                                                                                                                                                                                                                                                                              1. Results Summary
                                                                                                                                                                                                                                                                                                                                                                                                1. Financial Benefits
                                                                                                                                                                                                                                                                                                                                                                                                2. Transition to Process Owners
                                                                                                                                                                                                                                                                                                                                                                                                  1. Responsibility Transfer
                                                                                                                                                                                                                                                                                                                                                                                                    1. Ongoing Support

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                                                                                                                                                                                                                                                                                                                                                                                            4. Integrating Lean and Six Sigma