Topic 1

What is Quality (Introduction)

• Understand the history of quality
• Gathering the voice of the customer
• Garvin’s five definitions of quality
• Definitions of quality from quality gurus
• Differences in quality between products and services

Topic 2

Enterprise-wide View (Introduction)

• Understand the history of continuous improvement
• Six Sigma as a Value
• Six Sigma as a Measure
• Six Sigma as a Metric
• Rolled Throughput Yield
• Six Sigma Approach
• Six Sigma Process
• Six Sigma System
• Six Sigma System

Topic 3

Lean (Introduction)

• Understand the history of Lean and the value it brings to an organisation
• The philosophy and goals of Lean Manufacturing
• Understand how Lean integrates with Six Sigma

Topic 4

Six Sigma Roles and Responsibilities (Introduction)

• Understand Six Sigma key players
• Understand team stages in six sigma projects
• Understand the different modes of team communication

Topic 5

Understanding the Define Phase of Six Sigma (Define Phase)

LSS Green Belt Define Phase – The Define Phase of the DMAIC methodology is constructed to introduce the fundamentals of Lean Six Sigma.

• Describe the two stages of the Define phase<

Topic 6

Six Sigma Important Stakeholders (Define Phase)

• Describe the stakeholders in Six Sigma projects
• Understand how the changeover to Six Sigma implementation affects stakeholders

Topic 7

Voice of the Customer (Define Phase)

• Understand the importance of the Voice of the Customer is Six Sigma projects
• Comprehending the Voice of the Customer

Topic 8

Critical to Quality Flowdown (Define Phase)

• Understand the definition and purpose of Critical to Quality
• Understand the Critical to Quality steps or flowdown

Topic 9

Performance Metrics (Define Phase)

• Explain what performance metrics are and they can be used to measure the effectiveness and efficiency of a process and establish goals for a project’s anticipated outcome
• Explain the difference between process and business metrics
• Explain the impact of the cots of poor quality (COPQ)
• Know what questions to ask to determine the quality of the performance metrics

Topic 10

Project Charter (Define Phase)

• Understand the purpose of a project charter
• Understand the requirements and the elements of a project charter
• Know how to phrase a problem statement
• Know what questions to ask to determine the quality of the performance metrics

Topic 11

Wrap Up & Action Items (Define Phase)

Topic 12

Processes and Process Characteristics (Measure Phase)

LSS Green Belt Measure Phase – The Measure Phase of the DMAIC methodology is constructed to introduce important Lean Six Sigma tools for characterising your business issues.

• Define a process
• Explain different types of processes
• Explain different process characteristics

Topic 13

Process Maps and Flow Chart (Measure Phase)

• Understand how to create a process map
• Understand the different types of process maps
• Describe process flow metrics and how they are used

Topic 14

Data Types and Measurement Scales (Measure Phase)

• Describe the difference between attribute and variable data
• Understand the difference between continuous and discrete data
• Understand the difference between nominal, ordinal, interval and ratio scales
• Know how to express data in different scales

Topic 15

Data Collection (Measure Phase)

• Understand how to choose different data collection methods
• Know how to use check sheets and when to use different types of check sheets
• Understand the advantages and disadvantages of automated gauging
• Know how to code data and the advantages and disadvantages of coding data
• Understand the concepts of data integrity and accuracy

Topic 16

Sampling Strategies (Measure Phase)

• Understand the concept of sampling and the different types of sampling strategies
• Apply probability sampling strategies
• Apply non-probability sampling strategies
• Know how to calculate and determine sample size for continuous and discrete data

Topic 17

Fishbone Diagram (Measure Phase)

• Understand the purpose and meaning of the Ishikawa or Fishbone diagram
• Apply the Fishbone diagram
• Apply non-probability sampling strategies
• Know how to calculate and determine sample size for continuous and discrete data

Topic 18

Relational Matrix /Prioritisation Matrix (Measure Phase)

• Understand that a relational matrix is a tool used to measure which of the input variables has the greatest effect on output
• Know when and how to use a relational matrix
• Understand the differences between the X-T matrix and the Quality Function Deployment (QFD)

Topic 19

Basic Statistics (Measure Phase Module)

• Explain the various statistics used to express location and spread of data
• Describe the characteristics of a Normal Distribution
• Explain the measures of dispersion
• Understand and use measures of symmetry
• Explain the Central Limit Theory
• Explain frequency distribution

Topic 20

Graphical Methods (Measure Phase)

• Understand how to construct histograms and differences in distribution shape
• Construct a histogram using Minitab
• Construct a stem and leaf plot
• Construct a box plot
• Construct a run chart
• Explain the significance of P values in relation to hypotheses
• Compare graphical methods and decide which is best to use

Topic 21

Gauge R and R (Measure Phase)

• Understand the concept of gauge repeatability and reproducibility
• Understand the concepts of accuracy, precision, linearity, stability and bias
• Apply Gauge R and R
• Apply Gauge R and R regression analysis

Topic 22

Process Capability Analysis (Measure Phase)

• Understand causes of variation
• Estimate Capability for Continuous Data
• Describe the impact of Non-normal Data on the analysis presented in this module for Continuous Capability
• Estimate Capability for Attribute Data

Topic 23

Wrap Up & Action Items (Measure Phase)

Topic 24

Graph and Data Analysis (Analyse Phase)

• Construct a scatter diagram
• Understand correlation and regression analysis
• Apply the method of least square
• Apply a simple linear regression model
• Apply multiple linear regression analysis

Topic 25

Multi-Vari Analysis (Analyse Phase)

• Perform a Multi-Vari Analysis
• Interpret and a Multi-Vari Graph
• Identify when a Multi-Vari Analysis is applicable

Topic 26

Intro to Hypothesis Testing (Analyse Phase)

• Articulate the purpose of Hypothesis Testing
• Explain the concepts of the Central Tendency
• Be familiar with the types of Hypothesis Tests
• Statistical inference
• Understand the concepts between statistical and practical significance
• Calculate point and interval estimations
• Calculate margin of error and sample size
• Calculate confidence intervals

Topic 27

Hypothesis Testing Normal Data (Analyse Phase)

• Determine appropriate sample sizes for testing Means
• Conduct various Hypothesis Tests for Means
• Properly Analyse Results
• Be able to conduct Hypothesis Testing of Variances
• Understand how to Analyse Hypothesis Testing Results

Topic 28

Hypothesis Testing Non-Normal Data (Analyse Phase )

• Conduct Hypothesis Testing for equal variance
• Conduct Hypothesis Testing for Medians
• Analyse and interpret the results
• Calculate and explain test for proportions
• Calculate and explain contingency tests

Topic 29

Pareto Charts (Analyse Phase)

• Explain the objectives of a Pareto chart
• Construct a Pareto chart
• Test proportion = specified value
• Test if two proportions are equal

Topic 30

Failure Mode and Effects Analysis (Analyse Phase)

• Explain the of conducting FMEA and its various elements
• Explain and calculate Risk Priority Number
• Understand procedures involved in conducting FMEA
• Understand differences of design and process FMEA
• Explain advantages and disadvantages of conducting FMEA

Topic 31

Non-Value Added Activities (Analyse Phase)

• Understand the seven types of process waste
• Understand the difference between value and non-value added activities
• Identify non-value added activities from process maps

Topic 32

Value Stream Mapping (Analyse Phase)

• Understand VSM process and symbols used
• Create a Value Stream Map
• Understand the difference between cycle time and takt time
• Know when to use Lean Systems
• Construct a spaghetti chart
• Outline the benefits of VSM

Topic 33

Wrap Up & Action Items (Analyse Phase)

Topic 34

Generate New and Re-used Solutions (Improve Phase)

LSS Green Belt Improve Phase – The Improve Phase of the DMAIC methodology is constructed to introduce important Lean Six Sigma tools for properly controlling solutions.

• Generate solution ideas
• Apply six thinking hats to evaluate solutions
• Understand the role of bench-marking solutions
• Understand the concept of process entitlement

Topic 35

5S (Improve Phase)

• Understand the 5 concepts in the 5S model
• Understand the effect of 5S on improvements

Topic 36

Evaluate and select top solution (Improvement Phase)

• Understand the approach to design and implement a solution
• Prepare process maps that reflect the desired state
• Understand the concept of poka-yoke (mistake proofing)
• Understand the steps to pilot the top solution

Topic 37

Designing Experiments (Improve Phase)

• Understand the concept of experiment design and the terminology
• Describe the difference between a physical model and a DOE model
• Explain an OFAT experiment and its primary weakness
• Shown Main Effects Plots and interactions, determine which effects and interactions may be significant
• Create a Full Factorial Design

Topic 38

Kaizen and Kanban and Theory of Constraints (Improvement Phase)

• Understand the concept of Kaizen and Demming cycle and a Kaizen event
• Understand the concept of Kanban and the Push vs Pull system of production
• Know how to create strategic buffer
• Understand the Theory of Constraints and the five focusing steps

Topic 39

Wrap Up & Action Items (Improve Phase)

Topic 40

Statistical Process Control – SPC (Control Phase )

• Describe the elements of an SPC Chart and the purposes of SPC
• Understand how SPC ranks in defect prevention
• Describe the special cause detection rules
• Design subgroups if needed for SPC usage
• Understand the differences between Attribute and Continuous Control Charts
• Create an I-MR control chart
• Create an X-bar R chart
• Create an X-bar S chart
• Create P and Np charts
• Create a U chart
• Create time-weighted charts
• Explain the purpose of a Visual Factory

Topic 41

Total Productive Maintenance (Control Phase)

• Explain the concept of TPM
• Understand the 8 pillars of TPM
• Explain the benefits of TPM

Topic 42

Selecting Solutions (Control Phase)

• Conduct a cost benefit analysis to select the best solution
• Understand the requirement to reanalyse the measurement system
• Understand how the Lean tools depends on each other
• Understand how tools must document the defect prevention created in the Control Phase

Topic 43

Control Plan (Control Phase)

• Understand the purpose of a Control Plan
• Understand the purpose of a documentation plan
• Understand the concept of lessons learned

Topic 44

Wrap Up & Action Items (Control Phase)