This comprehensive program covers the Lean Six Sigma methodology, combining Lean’s speed and efficiency with Six Sigma’s focus on quality and consistency. The course is structured to take participants through the DMAIC (Define, Measure, Analyze, Improve, Control) framework, providing the tools needed to eliminate waste and reduce process variation.

Course Objectives:

• Understand the core principles of Lean and Six Sigma.
• Master the DMAIC methodology for process improvement.
• Apply statistical tools to identify and analyze root causes of defects.
• Learn how to lead process improvement projects and teams.
• Achieve measurable financial and operational results through waste reduction.

Target Audience:

• Quality Professionals and Process Engineers.
• Operations Managers and Project Leaders.
• Individuals seeking Lean Six Sigma certification.

Course Outline:

Day 1: Define Phase & Lean Fundamentals

• Introduction to Six Sigma and Lean philosophy.
• Defining the Project Charter and Problem Statement.
• Identifying Customer Requirements (Voice of the Customer – VOC).
• SIPOC Diagrams and Value Stream Mapping (VSM).
• Lean tools: 5S, Just-in-Time (JIT), and Muda (Waste) identification.

Day 2: Measure Phase

• Mapping the Current State process.
• Basic Statistics for Quality: Mean, Median, Mode, and Standard Deviation.
• Data Collection Plans and Measurement System Analysis (MSA).
• Calculating Process Capability (Cp and Cpk).

Day 3: Analyze Phase

• Identifying Potential Root Causes (Fishbone & 5 Whys).
• Hypothesis Testing and Correlation analysis.
• Failure Mode and Effects Analysis (FMEA).
• Data Visualization: Pareto Charts, Histograms, and Scatter Plots.

Day 4: Improve Phase

• Generating and Selecting Creative Solutions.
• Piloting and Testing Improvements.
• Implementation Planning and Stakeholder Management.
• Mistake Proofing (Poka-Yoke) and Kaizen events.

Day 5: Control Phase & Project Leadership

• Developing Control Plans and Standard Operating Procedures (SOPs).
• Statistical Process Control (SPC) and Control Charts.
• Sustaining the gains and project handover.
• Leading Six Sigma teams and change management.