Course Methodology

This course is consultant-led and classroom-based. The instruction is a blend of lectures, applications, individual exercises, and group work. Laptops will be extensively used during the course to practice Minitab. Various activities and an entire case study will be used to direct and illustrate the implementation of a project. Games and discussions will also be used to enrich course delivery.

This interactive and fully narrated course follows the Certified Six Sigma Green Belt (CSSGB) Body of Knowledge (BoK). Using real-world examples and over 100 activities, the course is designed to help you prepare for the ASQ CSSGB certification exam.

Course Objectives

By the end of the course, participants will be able to:

• Apply the principles of the Six Sigma 'DMAIC' performance improvement model
• Examine in detail the various elements of building a complete project for improvement
• Implement commonly used statistical analysis using statistical tools and software
• Analyze types of waste and defects by applying Lean and Six Sigma
• Review the content covered by the CSSGB BoK and within the ASQ CSSGB exam

Target Audience

Individuals from all departments, including finance, quality, business operations staff, and process owners. The course also suits those preparing for Green Belt certification, as it covers the Body of Knowledge required for ASQ Green Belt Certification (CSSGB).

Target Competencies

• Applying Six Sigma
• Computing process capability
• Understanding descriptive and inferential statistics
• Interpreting statistical process control
• Understanding Lean principles

Six Sigma and Organizational Goals

• Value of Six Sigma
• History and origins
• Cost of poor quality (COPQ)
• Organizational goals and Six Sigma projects
• Organizational drivers and metrics
• Design for Six Sigma (DFSS) methodologies

Define Phase: Tools and Methods

• Project identification and selection
• Process elements: Inputs and outputs
• Process owners and stakeholders
• Drafting the project charter
• Scope and problem statement
• Customer identification
• Voice of the Customer (VoC) and Critical to Quality (CTQ)
• Drafting SIPOC
• The case study
• Business results for projects
• Process performance—defects per unit (DPU)
• Rolled Throughput Yield (RTY)
• Defects per Million Opportunities (DPMO)
• Introduction to level calculations in Six Sigma
• Process and performance capability
• Process capability indices, 'Cp' and 'CpK'
• Project management basics
• Team dynamics and performance
• Introduction and tutorial sessions on Minitab
• Management and planning tools

Measure Phase: Introduction and Tools

• Process analysis and documentation
• Probability and statistics
• Statistical distributions
• Collecting and summarizing data
• Types of data and measurement scales
• Sampling and data collection methods
• Descriptive statistics
• Graphical methods
• Measurement System Analysis (MSA)
• Importance of the CE matrix
• Data normality

Analyze Phase: Introduction and Tools

• Statistical process control
• Control charts and stability issues
• Qualitative analysis and quick wins
• Process mapping
• Exploratory data analysis
• Hypothesis testing
• Design of Experiments (DOE)
• Root cause analysis
• Review of the seven quality tools
• Graphical analysis
• Histograms
• Analysis of Variance (ANOVA) and multi-plot diagrams
• Failure Mode and Effect Analysis (FMEA)

Improve and Control Phases: Introduction and Tools

• Piloting and implementation
• Pre and post capability
• Test of hypothesis
• Not golfing like Tiger? Six Sigma can help
• Class exercise: The catapult experiment
• Control phase
• Control plans
• Lean tools for process control

Introduction to Lean Enterprise

• Lean or Six Sigma?
• Lean principles in the organization
• Types of waste: Muda, Muri, and Mura
• Value Stream Mapping
• Spaghetti Diagram for distance analysis
• Other Lean tools (e.g., Pull system, POUS)
• Visual Management (5S)
• Mistake proofing