Lean Six Sigma Leadership Training: 3 days
Prerequisite: Lean Six Sigma Introduction Training
The following outlines goals/deliverables for an introductory Lean/Sigma training program. The focus will on an accelerated walk through to introduce participants to essential techniques and approaches associated with Lean/Sigma to sustain continued organizational growth. The program prepares participants for involvement in actual projects designed to improve and advance the operations and services provided by an enterprise. Participants will be introduced to the DMAIC* roadmap and typical tools and methods used in Lean/Sigma deployment.
*Define, Measure, Analyze, Improve, Control
Day 1 - How to define, prioritize, and establish requirements for continuous improvement projects (Define and Measure phases).
- Identifying common elements found in most continuous improvement and quality improvement efforts.
- Working with ideas generated through team involvement - team dynamics and results.
- Source and selection of projects and how to stay focused on customer requirements.
- How to use process observations and measurements in problem solving.
- Day 1 tools: Project prioritization matrix, Calculation of DPMO (Defects per Million Opportunities), Examples of Project Charters, Project Selection Matrix, SIPOC (Suppliers, Inputs, Process, Outputs, Customer), Value Stream Mapping Templates, Pareto, Critical to Customer (CTC) Trees.
Day 2 - Techniques used to analyze data/information, identify root cause, and apply results to improve processes.
- Case Study to introduce DMAIC tools applied to a manufacturing example.
- Continuation of Measure Phase tools and importance of evaluating measurement systems as part of overall process improvement.
- Understanding of variation through a practical demonstration.
- Develop the use of control charts as a tool to understand and reduce variation.
- Introduction of basic tools in the Analyze & Improve Phases.
- Day 2 tools: Process Mapping, Cause & Effect Matrix, Control Charts, Measurement System Evaluations (MSE), Prioritizing process variables (x's), Box Plots, FMEA (Failure Mode and Effects Analysis), Introduction/Elements of DOE (Design of Experiments)
Day 3 - How to sustain improvements and find/apply new best practices (Improve and Control Phases). Further discussions of the role of a "Project Champion".
- How to determine critical x's through active data collection and experimentation.
- Elements of successful project management.
- Mentoring/coaching Green Belts and managing project expectations.
- Validating performance against bottom line results
- Avoiding pitfalls associated with Six Sigma deployments
- Day 3 tools: Continuation of DOE, Project Management Tools, Improvement Process Check List, Control Charts, Control Plan, Poka-Yoke Options, Recommended resources of information (books, websites, and free Internet information).
At the completion of the program, participants will be able to contribute in the following areas:
- Fundamental practices in CI and how to use available resources for improving company performance.
- A sustaining process to identify and prioritize L/S projects and an understanding of the responsibilities of a Project Champion for supporting practitioners (Green & Black Belts)
- Understand where and how to apply a phased approach in problem solving activities.
- How reducing variability leads to improved performance.
- How to enhance and strengthen team involvement in cross-functional problem solving.