Six Sigma Training Workshop
Introduction
Survival in business today depends not only on hard work, good
products, and growing markets, but also on continuous improvement
of services and products, innovation, and on identifying and
meeting the needs of customers.
In order to achieve these goals, there is a growing need for
business managers and professionals to promote continuous learning
within their organizations. This philosophy is practiced
at leading organizations and it has been the primary reason for
their successes in maintaining industry superiority. This
workshop can be tailored to the needs of any organization, depending
on what has been learned previously and what objectives for improvement
have been identified.
The Six Sigma Training Workshop is an advanced training course
in process improvement and problem solving methods. Six
Sigma has a proven track record as a tool for achieving operational
excellence. The workshop is designed to provide the participants
with knowledge of the theories and techniques utilized in a Six-Sigma
environment.
Six Sigma Workshop
The Six-Sigma workshop is an interactive training workshop. Six
Sigma theories and methods are presented in the following topics. The
typical program is 40-48 hours:
- Introduction to Six Sigma DMAIC
- Understanding Variation, Process Capability
- Process Mapping
- Study of Cycle Time
- Quality Improvement Tools
- Process Control Tools
- Failure Modes and Effects Analysis
- Measuring System Evaluation (Gauge R&R)
- Design of Experiments
- Implementation of Six Sigma
Each workshop session will include objectives and goals, questions
and answers, and exercises and experiments to reinforce the learning.
The material covered in each subject will be as follows:
1. Introduction to Six Sigma
In addition to
reviewing the training plan for the entire workshop,
the following topics are presented:
- The origins of six sigma.
- What is six sigma and what is it used for?
- What are the benefits of six sigma?
- Who is using six sigma?
2. Understanding Variation, Process Capability
This module sets the tone for the remainder of the workshop. The
discussions will include all terms, equations, calculations,
and interpretations of variation and process capability. The
following subjects will be discussed in detail, followed by examples
and classroom exercises:
- What is variation?
- Different types of variation.
- What are normal distribution, mean, and standard deviation?
- How does variation equate into defects and costs?
- How to measure variation.
- What is process capability?
3. Process Mapping
Process mapping is a vital part of every problem solving and
quality improvement effort. During this session the importance
of process mapping will be discussed and various types of process
maps will be reviewed.
4. Study of Cycle Time
Study of cycle time is a powerful method for improving productivity,
efficiency, and reducing cost. It builds on the knowledge
gained from process mapping. The participants will learn
the methods used to identify waste and non-values-added activities
in a process, and how to determine a baseline for the improvement
efforts.
5. Quality Improvement Tools
Quality improvement tools are the foundation of the problem
solving and quality improvement process. Although team
building methods are not the focus of this workshop, the quality
improvement process constitutes a sizable portion of many team
activities. This session focuses on the common steps in the problem
solving and quality improvement process as well as the tools
used at each step of the process. Discussions will include
the “how to’s” such as problem or improvement
selection, understanding, and analysis, idea generation, improvement
and implementation planning as well as reviewing the common pitfalls.
6. Process Control Tools
This session will focus on understanding the process control
charts for both variable and attribute type data. The discussions
will include such topics as how and when to collect data, the
components of control charts, the criteria for control chart
selection, mean and control limits calculations, data interpretation,
trends, and pitfalls in using control charts.
7. Failure Modes and Effects Analysis (FMEA)
FMEA is a powerful tool for improving the quality and reliability
of products and services. The session will remove the myth
surrounding FMEAs. All components of FMEA, including failure
mode identification, quality risk assessment, implementation
of preventive measures, and practical applications of FMEA will
be discussed in detail followed by hands-on exercises to reinforce
the learning.
8. Measurement System Evaluation (MSE)
MSE is also known as “Gauge Repeatability & Reproducibility” (Gauge
R & R). The session focuses in detail on variation
of the measurement process and reviews the techniques used to
detect the sources of errors and such variation. The discussion
also will include how to use the information from MSE studies
to improve the reliability of the measurement system and overall
product quality.
9. Design of Experiments (DOE)
DOE is an advanced statistical tool whose purpose is to identify
and perform only the experiments that are necessary to evaluate
a problem or an improvement solution. The session will
discuss the principles and methods of DOE. The common applications
will be discussed followed by simple hands-on experiments to
reinforce the learning.
10. Implementation of Six Sigma
The final part of the workshop will begin with a quick review
of the material covered during the previous sessions. The
participants will then be grouped into small teams. Each
team will be assigned a case. The teams will use the knowledge
gained from the workshop to analyze the case and present solutions
and improvement plans.
In some cases, the group will be working on a project throughout
the training and part of this session is used for presentations
of the projects.
The session and the workshop will conclude with discussions
about implementation of Six Sigma thinking within organizations. It
will cover key concerns such as “how to implement” and “where
to start.”
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