Lean Six Sigma DMAIC Essentials

This online short course provides 9 Lessons, plus 5 videos, detaling the application of the Six Sigma DMAIC methodology to lean and process improvement projects. 

Each lesson includes:

• Detailed slides with Notes.
• Interactive Exercises.
• Study Guide Questions to test your knowledge.
• Online Glossary and References for further information.

1. Six Sigma Projects
   1. Project Focus
      1. Is it a Six Sigma Project?
      2. Customer Focused Projects
      3. Video: Customer Focus Overview
   2. Selecting Projects
      1. Video: Project Selection Using PM
      2. Video: Consensus Criteria Method
   3. Estimating Project Benefits
   4. Overview of DMAIC methodology
   5. Project Reporting
   6. Quiz
2. DEFINE Stage Tools & Objectives
   1. Define Stage Objectives
   2. Project Charter: Use and Development
      1. Work Breakdown Structure.
      2. Pareto Diagrams.
      3. Process Maps.
      4. SIPOC
      5. Matrix Diagrams
   3. Quiz
3. DEFINE: Metrics & Deliverables
   1. Critical to Quality (CTQ) Metrics
      1. Throughput Yield (and comparison to traditional yield)
      2. Rolled Throughput Yield
      3. Video: Rolled Throughput Yield Calculations
      4. Normalized Yield
      5. DPMO: Use and Misuse
      6. Sigma Level
      7. Video: DPMO & Sigma Level Calculations
   2. Critical to Schedule (CTS) Metrics
      1. Cycle Time
      2. Process Cycle Efficiency
      3. Process Velocity
      4. Overall Equipment Effectiveness (OEE)
   3. Relation of CTQ and CTS Metrics to Critical to Cost (CTC) Metrics
   4. Quiz
4. DEFINE: Project Scheduling
   1. Scheduling Project Activities & Events
   2. Gantt Chart
   3. Critical Path Analysis / Activity Network Diagram.
   4. PERT Analysis
   5. Quiz
5. DEFINE: Change Management and Six Sigma Teams
   1. Problems with Change
   2. Achieving Buy-In
   3. Team Formation, Rules & Responsibilities
      1. Stages of Team Development
      2. Overcoming Problems
   4. Consensus Building
      1. Affinity Diagram
      2. Nominal Group Technique
      3. Prioritization Matrix
   5. Quiz
6. Measure Stage Tools and Objectives
   1. Measure Stage Objectives
   2. Process Definition (Flowcharts, Process Maps, SIPOC)
   3. Metric Definition
   4. Establishing Process Baseline
      1. Enumerative vs. Analytic Statistics.
      2. Process Variation (Deming's Red Bead)
      3. Benefits of Control Charts.
      4. Requirements vs. Control (Tampering)
      5. Control Chart as Process Baseline Tool
   5. Quiz
7. Analyze Stage Tools & Objectives
   1. Analyze Stage Objectives
   2. Definition of Waste
   3. Analyzing Process for NVA
      1. Cycle Efficiencies
      2. Lead Time and Velocity
      3. Takt Time
   4. Methods to Increase Velocity
      1. Standardization
      2. Optimization
      3. Spaghetti Diagrams
      4. Level Loading
      5. When are Batches More Efficient?
      6. Setup Reductions
   5. Quiz
8. Improve Stage Tools and Objectives
   1. Improve Stage Objectives
   2. Tools to Prioritize Improvement Opportunities
   3. Defining New Process Flow
      1. Lean Tools to reduce NVA and Achieve Flow
      2. 5S
      3. Level Loading
   4. Tools to Define & Mitigate Failure Modes
      1. PDPC
      2. FMECA
      3. Preventing Failures
   5. Reference to Tools for Defining New Process Levels
   6. Quiz
9. Control Stage Tools & Objectives
   1. Control Stage Objectives
   2. Methods of Control
   3. Control Plans
   4. Training
   5. Measuring Improvement
   6. Quiz

Paul Keller, Quality America's President, has developed and implemented successful Six Sigma and Quality Improvement programs in service and manufacturing environments. Paul has been with Quality America since 1992, where he has:

• Developed and managed systems for overall operations, including quality improvement, product development, partner relations, marketing, sales, order fulfillment and technical support.
• Provided statistical expertise to our customers, as well as internal Software Development, Sales and Technical Support teams.
• Developed and facilitated Six Sigma related courses, including Quality Management, Statistical Process Control (SPC), and Designed Experiments, to hundreds of our companies in a wide variety of industries including Roche Pharmaceuticals, Core3 Inc. Business Process Outsourcing, US Army, MacDermid Printing Solutions, Boeing Satellite, Dow Corning, Antec, Pfizer, Warner Lambert, and many others.

Paul has authored a number of well-received publications, including:

•    Six Sigma Handbook: Fourth Edition (New York: McGraw Hill, 2013) and Six Sigma Handbook: Third Edition (New York: McGraw Hill,2009). Paul wrote all the new material for these editions, edited the earlier material, and authored a series of instructional videos for McGraw-Hill's Access Engineering online program. (These videos are also included in our online training). This text has sold over 150,000 copies, a true best-seller in the market!
•    Handbook for Quality Management, Second Edition: A Complete Guide to Organizational Excellence (New York: McGraw Hill, 2012) Paul wrote all the new material for this edition, and edited the earlier material.
•    SPC Demystified (New York: McGraw Hill, 2011).
•    Six Sigma Demystified: Second Edition (New York: McGraw Hill, 2010) and Six Sigma Demystified (New York: McGraw Hill, 2005). Over 50,000 copies.
•    Manufacturing Handbook of Best Practices (Boca Raton: St. Lucie Press, 2002) Contributing Author.
•    Six Sigma Deployment (Tucson: QA Publishing, 2001).
•    Six Sigma Study Guide (Tucson: QA Publishing, 2001) Co-author.
•    Handbook for Quality Technicians and Mechanical Inspectors (Tucson: QA Publishing, 2000) Contributing Author.
•    Handbook for Quality Management (Tucson: QA Publishing, 2000) Contributing Author.
•    Numerous articles in professional trade magazines,conference proceedings, and Quality America's Knowledge Center (1992-present).