Six Sigma Green Belt

• History of Quality (Deming, Juran, JIT, Ishikawa, Taguchi, etc.)
• Evolution of Six Sigma
• Defining Six Sigma — philosophy and objectives
• Overview of Six Sigma DMAIC process

1. Identifying and documenting stakeholder requirements

• Identifying stakeholders and customers
• Data collection and analysis
• Determining critical requirements

2. Project selection criteria

• Identifying performance metrics
• Using financial criteria to evaluate project benefits
• Maximizing project benefits for the organization

3. Project Planning

• Creating a project charter
• Charter negotiation

4. Managing team dynamics

• Initiating teams
• Stages of team evolution
• Maslow’s hierarchy of needs
• Motivation techniques
• Conflict resolution techniques
• Management / leadership styles
• Roles in a project

5. Important project management and planning tools

1. Inputs — Need for Six Sigma project, executive management sponsorship, core team identification

2. Tools

• Organization hierarchy
• High-level process maps
• High-level Pareto charts
• Idea generation and categorization tools

3. Outputs

• Project charter
• Established metrics
• Problem statement
• Roles and responsibilities

1. Objectives of Measure phase

2. Inputs — the outputs of the Define phase

3. Tools

• Data collection tools and techniques
• Measurement scales
• Validation techniques (Gauge R & R)
• Statistical distributions
• Data mining
• Run charts
• Process map
• Stakeholder tools
• Process costs

4. Outputs

• Well-defined processes
• Baseline process capability
• Process parameters affecting CTQs
• Cost of poor quality (COPQ)
• Measurement system

1. Objectives of Analyze phase

2. Inputs — outputs of the Measure phase

3. Tools

• Ishikawa diagram
• Failure mode and effects analysis
• Hypothesis testing
• Process capability study

4. Outputs

• Important causes of defects
• Special and common causes of variation
• DPMO and sigma level

1. Objectives of Improve Phase

2. Inputs – outputs of the Analyze phase

3. Tools

• Returns on investment
• Solution design matrix
• Design of experiment
• Taguchi robustness concepts
• Response surface methodology
• Project planning and management tools
• Prototypes

4. Outputs

• Cost / benefit for different solutions
• Selection of solutions for implementation
• Implementation plan

1. Objectives of Control phase

2. Inputs — outputs of the Improve phase

3. Tools

• Control plan
• Statistical process control
• Lean enterprise
• 5S
• Kaizen
• Kanban
• Total productive maintenance
• Measurement system reanalysis

4. Outputs

• Implemented solutions
• Revised measurement system
• Control plan for sustaining benefits
• Improved process capability
• Lessons learned

1. Case Study Part 1

2. Case Study Part 2

3. Case Study Part 3