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:

1. Introduction to Six Sigma DMAIC
2. Understanding Variation, Process Capability
3. Process Mapping
4. Study of Cycle Time
5. Quality Improvement Tools
6. Process Control Tools
7. Failure Modes and Effects Analysis
8. Measuring System Evaluation (Gauge R&R)
9. Design of Experiments
10. 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.”