SIX SIGMA was developed by Motorola in 1986 as a management strategy for business that depends on statistical analysis to improve the production process of the company. SIX SIGMA methodology was originally used to reduce variation in electronic manufacturing processes in Motorola Inc in the USA. After more than 25 years it is now the most popular management and Problem solving methodology. SIX SIGMA is a structured and disciplined methodology using facts, data, and required statistical analysis to improve and reinvent business processes across industries. A SIX SIGMA process will be 99.9997% defect free or produce only 3.4 Defects per million opportunities. LEAN MANUFACTURING was adopted by Toyota Motor Corporation and is a set of tools developed to reduce waste associated with the flow of materials and information in a process from beginning to end. The goal of LEAN MANUFACTURING is to identify and eliminate non-value added activities and steps in a process to improve turn-around time by streamlining production, improve quality and eventually enhance customer loyalty. The technique helps to speed up action and decision-making process of a company while decreasing inefficiencies in the production and increasing the quality of the products. LEAN SIX SIGMA is an integrated approach with a combination of both the concepts — SIX SIGMA and LEAN MANUFACTURING. LEAN focuses on improving efficiencies by eliminating waste and SIX SIGMA aims to get rid of defects in a defined and stable process. The concepts and methodologies of LEAN SIX SIGMA are universally applicable to all types of organizations. LEAN SIX SIGMA is used as a business performance methodology, all over the world across industries as diverse as manufacturing units, aerospace, banks, hospitals, software development, retail companies, contact centers, education and even government departments. This list is endless and organizations have invested in training, culture building and overall skill development to be ahead of competition by meeting and exceeding the needs of the customers. The Training helps in improving the lateral thinking tips and will give you an edge from others in the crowd. This training enhances the approach to address real life problem solving and innovation.

Topics Covered

Day 1 a) Yellow Belt Course Contents (Duration of course – 1 Day) : 1. Basics about Six Sigma: a) Origin and History of Six sigma b) DMAIC Lifecycle for Problem Solving c) Project Selection and Prioritization – A Practical Approach 2. What are LEAN TOOLS? a) Lean Principles in an Organization b) Lean Tools –5S, Seven Types of Wastes, Pull Theory 3. Change Management a) Change Management – Identification, Implementation, Tools, Stakeholder Management 4. Define Phase: a) CTQ , CTP Matrix b) Methods to collect customer feedback (e.g., surveys, focus groups, interviews, observation) c) Kano Model, Translating customer requirements d) Project Metrics e) Operational Definition f) SIPOC , Process Mapping , Functional Maps g) Project Charter - Prerequisites h) Defects, Defective, DPMO, DPO, Cost of Poor Quality (COPQ) i) Process failure mode and effects analysis ( PFMEA) & DFMEA 5. Measure Phase: a) Y=F(X) Diagram b) Data Types: Discrete and Continuous c) Data Collection Plan d) Types of Sampling plans e) Pareto Chart, Run Chart 6. Analyze Phase: a) Fish bone diagram : Cause and Effect analysis and diagram b) Introduction to control charts – Continuous and Discrete Data 7. Improve Phase: a) Idea Generation – Brain Storming b) Solution selection tools c) Designing an Implementation Plan 8. Control Phase: a) Ensuring Error Proofing - Poka Yoke b) Sustaining Improvement Results c) Developing Standard Operating Procedures d) Process and Change management 9. Project Closure: a) Capturing Project Learning / Project Documentation / Sign Off’s b) Written Exam 30 Multiple Choice Questions, Exam Duration :30 minutes LEAN SIX SIGMA GREEN BELT TRAINING PROGRAM This program is ideal for Individuals or Companies aspiring to be Change Agents, Project Managers, Facilitators and Consultants in the journey of Continuous Improvements and Innovation. They will be trained to improve a business and processes using DMAIC (Define, Measure, Analyze, Improve, and Control Phases) and LEAN MANUFACTURING concepts. Green Belt Course Contents (Duration of course – 1 Yellow Belt + 2 Days additional topics of Green Belt) : Day 2 1) Basic Concepts: a) Importance of Six Sigma – Philosophy, Key Business Drivers and Impact b) Organizational Performance Scorecard and Metrics c) Design for Six Sigma (DFSS) d) Developing a Business Case 2) What IS LEAN SIX SIGMA? a) Lean concepts and tools b) Kaizen Events c) A3 3) Define Phase: a) Quality Function Deployment (QFD) b) Team dynamics, importance of roles c) Project Metrics : Identification and prioritization d) Rolled Throughput Yield (RTY) e) Project Risk Analysis 4) Measure Phase: a) Measurement System Characteristics: Tolerance; Precision; Accuracy; Linearity, Stability b) Process Capability Indices like Cp, Cpk, Cpm, Zst, Zlt, Zshift, ppm (DPMO) c) Basic concepts of probability 5) Analyze Phase: a) Hypothesis Testing b) Linear correlation and regression Day 3 6) Improve Phase: a) More innovative brainstorming methods of Idea Generation b) Introduction to DOE c) Solution Piloting – Planning and future roadmap d) Evaluating solutions and Cost benefit analysis e) Solution selection tools – PUGH matrix f) Cost Benefit Analysis g) Designing an Implementation Plan 7) Control Phase: a) Sustaining Improvement Results b) Developing Standard Operating Procedures c) Process and Change management d) Using Control Charts to monitor ongoing process 8) Project Closure: a) Capturing Project Learning / Project Documentation b) Class Exercise : Summarize learning’s 9) Written Exam 60 Questions, Exam Duration :60 minutes

Who should attend

1. Quality Professionals involved in Quality Assurance, Quality Improvement and Quality Control 2. Project Leaders and Managers 3. Finance, Production and Inventory and Vendor Management Professionals 4. Senior and Top Management from SME and Other Industries 5. Operations Heads / Manager 6. Profit and Cost Centre Heads / Managers 7. HR and Management Consultant 8. MBA / MCA / BCA / BBA / B Tech / M Tech Final Year Students

Pre-requisites

Quality Background. Interest to Excel and grow.

What you need to bring

None

Key Takeaways

1. Get introduced and learn the basics of problem solving tools of LEAN SIX SIGMA Methodology 2. Learn a structured methodology which will change the way you solve business / real life problems 3. Develop readiness and expertise to lead Small and Medium-scale improvement projects 4. Acquire De-Jargonized knowledge of basic statistical tools which can be used in your current role 5. Improved outlook to improve customer services by designing more robust and consistent processes 6. Learn data backed and logic based decision making 7. Embrace skills to be a successful Change Agent and Ambassadors 8. Have End to End Process prospective and enhanced understanding of within and beyond team linkages 9. Enhanced resource management due to process Design and Implementation effectiveness. 1. Interactive classroom training with examples and case studies from various industries 2. Group Exercises, Case Studies and Excerpts of Industry Best Practices 3. Change and Project Management Tips and Tricks, and easy to use toolkit 4. Teach how to think, how to use tools and why 5. Practice of Techniques to challenge status quo and improve process efficiency 6. Sharing or pitfalls, do’s and don’ts from experience 7. Written exam with atleast 70% passing marks 8. Review and preliminary discussion on the projects participants may have initiated / undertaken