Lean Six Sigma Fundamentals
Overview
Lean removes waste and Six Sigma reduces variation; together they improve speed, cost and quality. This course introduces Lean Six Sigma concepts and the DMAIC method, with practical tools participants can use straight away on improvement projects in manufacturing or service settings.
Who should attend
Operations, quality and process improvement staff, supervisors, engineers and managers in manufacturing and service organisations.
Training methodology
Interactive presentations, practical exercises, case studies, group discussions, role-plays where relevant, and a personal action plan that participants apply in their own work.
Objectives
By the end of this course, participants will be able to:
- Explain Lean principles and the eight wastes
- Describe Six Sigma and the DMAIC method
- Map value streams and spot improvement opportunities
- Use basic statistical and Lean tools
- Scope and run a small improvement project
Course outline
Day 1Lean Thinking
- Origins and principles of Lean
- Value from the customer's view
- The eight wastes
- Flow and pull
- Standard work
- Waste walk exercise
Day 2Six Sigma and DMAIC
- Variation and its cost
- Sigma levels and defects
- The DMAIC roadmap
- Roles: champions and belts
- Selecting good projects
- Exercise: write a project charter
Day 3Define and Measure
- Voice of the customer and CTQs
- SIPOC diagrams
- Value stream mapping
- Data collection plans
- Measurement system basics
- Workshop: map a value stream
Day 4Analyse and Improve
- Basic statistics and graphs
- Root cause tools
- 5S and visual management
- Setup reduction and quick changeover
- Mistake-proofing
- Exercise: design improvements
Day 5Control and Sustain
- Control plans
- Introduction to control charts
- Standardising the new process
- Measuring benefits
- Leading a Lean Six Sigma culture
- Project plan for your workplace
