**Each programme delivered by industry experienced professionals. Please call us to discuss your specific requirements**

**Lean Sigma Introduction – 2 days **

**Our most popular foundation course. Geared to the participating group , it gives a practical run through of all the main techniques. Throughout the 2 days participants relate the material directly to their work challenges and projects and leave with action plans to apply. **

This course will give an introduction to the lean sigma process. The expected outcome is that the attendee will have a basic overview of the integrated usage of lean and six sigma tools.

**Course outline**

Introduction to Lean sigma

What is lean

What is six sigma

Basic terminology

Why lean and six sigma are complimentary

Measures of quality

Cost of poor quality (COPQ) and The Hidden Factory / Office

Lean techniques to prioritize improvements

8 wastes of lean

5S

Kaizen

Introduction to DMAIC and 8D as problem solving methodologies

Understanding variability

Data collection and analysis techniques

Process and Value Stream Mapping improvement

Work flow

KANBAN and Just in time (JIT)

Collecting and using data

SPC

Control charts

Control plans

**Six Sigma Introduction – 2 days**

This course will give an introduction to the six sigma process. The expected outcome is that the attendee will have a basic overview of the tools, elements and the usage of six sigma.

**Course outline
**Introduction to six sigma

What is six sigma

Basic terminology

Motorola / GE usage

Measures of quality

Cost of poor quality

Introduction to DMAIC problem solving methodology

Understanding variability

Data collection

Data analysis techniques

Process improvement

Control

SPC

Control charts

Control plans

**Lean Introduction – 2 days or 1 day overview**

This course will give an introduction to the lean principles and toolkit. The expected outcome is that the attendee will have a basic overview of the lean principles and usage.

**Course outline**

Introduction to lean

Why lean

Basic terminology

Toyota Production System overview

Lean Toolbox

8 wastes

5S

Kaizen

Work flow

Takt time

KANBAN

Just in time (JIT)

SMED

Total productive maintenance (TPM)

Error proofing

How a lean structure can be implemented

Work “families”

Training regimes

**Problem Solving – 2 days or 1 day overview**

This course will describe structured problem solving tools and practice their usage. The expected outcome is that the attendee will have an understanding of the various problem solving methods and when to use them.

**Course outline
**Introduction to problem solving

Structured vs unstructured

Basic problem identification

Cost impact of poor problem solving

Different structured approaches

DMAIC

8D

Defining the problem

Voice of the Customer and Voice of the Process (VOC and VOP)Critical to quality definitions

Data collection and measurement basics

Sampling

Capability

SPC

Basic data analysis tools

Histograms, Pareto etc.

Basic risk analysis

Developing new solutions

Error proofing

Implementation and control

**Data Measurement Techniques – 2 days**

This course will describe data measurement techniques and practice their usage. The expected outcome is that the attendee will have an understanding of the types of data, how to measure, collect it and validate the result.

**Course outline
**Introduction to lean sigma and data

What is lean sigma

Why lean and six sigma are complimentary

Types of data

Understanding variability

Data collection plans

Different types of variability patterns

Equipment R&R / Measurement system analysis / Gauge R&R

Calculation a process sigma and DPMO

Yield calculations

Sampling techniques

Confidence intervals

Data collection

Identifying the process problem

Brainstorming

**Data Analysis Techniques – 2 days**

This course will describe data analysis techniques and practice their usage. The expected outcome is that the attendee will have an understanding of the types of data, how to analyse and present it in the appropriate context.

**Course outline
**Introduction to lean sigma and data

What is lean sigma

Why lean and six sigma are complimentary

Types of data

Data collection plans

Different types of variability patterns

Data analysis toolbox

Histograms

Pareto

Run charts

Box plots

Regression

Multivariate analysis

Cause and effect diagrams / 5 why’s

Confidence intervals

Process mapping

Cause verification

**Process Improvement – 2 days**

This course will describe process improvement techniques and practice their usage. The expected outcome is that the attendee will have an understanding of what a process is, how to design a new process and improve an existing process.

**Course outline
**Introduction to lean sigma process improvement

What is lean sigma

Why lean and six sigma are complimentary

Process improvement methods

Generation of new solutions

Solution selection

Hypothesis testing – T test, ANOVA, Chi Squared

Solution selection matrix

Result analysis

Error proofing

Design of experiments overview

Methods of implementing process improvements

Sustaining improvement

Statistical control

Control plans

Process Scorecards

I, Xbar & R charts

Standardisation

Visual management

**Design of Experiments – 2 days**

This course will describe experimental design techniques and practice their usage. The expected outcome is that the attendee will have an understanding of the concept of DOE, the various models available and be able to select the most appropriate for a given situation.

**Course outline**

Introduction to designed experiments

Basics of experimentation

Different options available for experimentation

Repeatability

Randomisation

Models for designed experiments

Factorial experiments Interactions and effects

Advantages of factorial matrices

Multiple factor experiments

Best design selection

Nested designs

Robustness evaluation

Interaction tables

Variation reduction and process optimisation

Real situation approaches

**Statistical Process Control (SPC) – 2 days**

This course will describe statistical process control and practice its usage. The expected outcome is that the attendee will have an understanding of the concepts of process variation, how to measure, understand and control it.

**Course outline**

Introduction to six sigma and SPC

What is six sigma

Basic terminology

Motorola / GE usage

Measures of quality

Cost of poor quality

Understanding variability

Control Charts

Chart types – Xbar & R, Moving Range etc.

Baseline charts

Calculating control limits

Western Electric rules

Interpreting control charts

Process capability

Cp / Cpk

Individuals vs. subgroups

Ppk vs. Cpk

Single sided distributions

Skewed distributions

SPC programme implementation

**Failure Mode and Effect Analysis (FMEA) – 2 days or 1 day overview**

This course will describe failure mode and effect analysis and practice its usage. The expected outcome is that the attendee will have an understanding of the concepts of different failure modes, how to pro-actively analyse them, perform risk analysis and create risk mitigation action plans.

**Course outline**

Overview

What is FMEA

How does the process work

Purpose of FMEA

How is it used

Links to quality systems (ISO9000 etc.)

Design FMEA or Process FMEA

FMEA team selection

Steps to conduct a FMEA

Severity, occurrence and detection ranking

Creation of a control plan

FMEA and continuous improvement