SIX SIGMA BASICS

Six sigma Basics

Six sigma Basics is a Web-Based learning system for understanding the concept of Six sigma to the
employees of a company from Quality Excellence.

Features
This learning system provides visually powerful, interactive and animated explanations that enable you to
learn complex six sigma concepts with ease. Voice over explanations in simple language make the
Learning easy and anxiety-free. You can ask for a quote for web based learning course for online or
CD/Download type and work through.
Six sigma learning at a pace you find comfortable for learning. The self paced nature of learning will enable
you take the Six sigma course conveniently from your office or home, at an hour convenient to you.
Teaches Six Sigma terminology
Translates and explains common Six Sigma acronyms, such as CTQ, CTC, DPMO, DFA, DFM, DMAIC,
DMADV, so that project team members don’t get lost in discussions
Suggests how to find improvement projects
Six Sigma basics includes techniques for selecting projects; considering factors such as potential benefits
relative to the resources needed, objectives, feasibility, and scope.
Helps employees understand their role in the process
Six Sigma basics looks at the roles of management, facilitators, teams, and others in the organization.
Save time and money
Stop wasting key resources developing and conducting classroom training. Computer-based training
requires 40-60% less training time than traditional classroom training which means less time away from the
job.
Ensures that everyone understands the process
Six Sigma shifts the focus from training to results, emphasizing learning tools and techniques as you go. For
this to work, everyone needs a basic understanding of the Six Sigma process.

System requireents

• IBM or Compatible 486 DX/66 Mhz or better with mouse.

• Windows 3.1 or higher & Minimum 8 MB RAM.
• Double speed CD ROM (Quad speed preferred)
• Super VGA (640X480,256 colours)monitor.
• A sound blaster or 100 % Compatible sound card.
SIX SIGMA –BASICS

Course outline

Section 1: Six sigma Organization & Infrastructure

1.1 What is the six sigma?
Meaning of six sigma, Approach ,Methodology, why six sigma-(Bottom line results,discliplined
approach-DMAIC,Customer &Process are focus, clearly defined measures of success, Variation
reduction, Prevention is goal)

1.2 Main concepts of Six Sigma

Calculate defects per million opportunities (DPMO),Financial Measures such as Return on investment
(ROI),Cost benefit analysis, Cost of Quality (COQ)

1.3 Enterprise wide deployment

Business processes and systems, six sigma and lean applications, Enterprise wide responsibilities
,Organizational roadblocks, Change management, Six sigma roles and responsibilities.

1.4 Organizational Process Management

Impact on stack holders, critical to x (CTX) requirements. Business performance measures (Balanced
scorecard & KPI

1.5 Team management

Types of teams, Team roles, Team member selection, and Launching teams. Team stages, Team
dynamics, team decision making tools. Management and Planning tools, Team performance & rewards.

Section 2: DMAIC Detail

2.1 DEFINE
A) Voice of customer: - Customer identification, Customer feedback, Customer requirements.
B) Project charter: problem statement, project scope, goals & objectives, project performance
measures.
C) Project tracking using Gantt charts and others.

2.2 MEASURE
A)Process characteristics
a)I/P and O/P variables, process flow metrics such as WIP,Work queue,takt time, cycle time and
throughput.
b) Process analysis tools such as VSM, Process maps, flowcharts, Procedures and work instructions
B)Data collection
a)Types of data such as Qualitative and quantitive data.Variaable and discrete data and convert
attributes data to variables when appropriate .
b) Measurement scales – nominal, Ordinal, Interval and ratio scales
c) Collecting data Developing data collection plan such as check sheets ,data coding techniques,
automated data collection.

C)Measurement systems

a)Measurement methods for both continuous and discrete data.

b) Measurement systems analysis use of R&R, Bias, Linearity, etc to analyze and interpret
measurement systems capability.
C) Measurement systems in the enterprise.
 D) Basic statistics
a)Basic terms such as proportion,mean,standard deviation.
b) Central limit theorm describe and use this theorem
c) Descriptive stastistics measures of dispersion, frequency distribution, cum frequency distribution..
D) Graphical Methods: box and whisker plots, run charts, scatter diagrams, histograms, normal
probability plots.
E) Valid statiscal conclusions: difference between enumerative and inferential statiscal studies and
evaluate their results to draw valid conclusions.

E)Probability

a)Commonly used distributions such as normal.poission,binormal,chiaquare,students t and f

distributions

F)Process Capability

a)process capability indices : Definition and calculation of Cp,Cpk to assess process capability .

b)Process performance indices : definition and calculation of pp.ppk to asses process performance.

c)Process capability of Attribute data : Calculation and of process capability and process sigma level
for attributes data.

d)Process capability studies : Identifying characteristics and specifications, developing sampling

plans and verifying stability and normality.

e)Process performance Vs Specification : Distinguish between process limits and specification limits
and calculate percent defective,PPM.DPMO,DPU,Process sigma.

2.3 ANALYZE

A. Measuring and modeling relationships between variables

1. Correlation coefficient
Calculate and interpret the correlation coefficient and its confidence interval, and describe the difference
between correlation and causation.

Multi-vari studies
Use and interpret charts of these studies and determine the difference between
positional, cyclical and temporal variation.

B. Hypothesis testing

1. Terminology Define and interpret the significance level, type I and type II errors of
statistical tests.
2. Statistical vs. practical significance
2. Define, compare and interpret statistical and practical significance.

Tests for means, variances and proportions

Use and interpret the results of hypothesis tests for means, variances and
proportions.
Analysis of variance (ANOVA)
Select, calculate and interpret the results of ANOVAs.

C. Failure mode and effects analysis (FMEA)

Describe the purpose and elements of FMEA, including risk priority number (RPN),
and evaluate FMEA results for processes, products and services. Distinguish between
design FMEA (DFMEA) and process FMEA (PFMEA), and interpret results from each.

C. Additional analysis methods

Root cause analysis

Define and describe the purpose of root cause analysis, recognize the issues involved in identifying a root
cause, and use various tools (e.g., the 5 whys,Pareto charts, fault tree analysis, cause and effect diagrams,
etc.) for resolving chronic problems.

Waste analysis
Identify and interpret the 7 classic wastes (overproduction, inventory, defects, over-processing, waiting,
motion and transportation) and other forms of waste such as resource under-utilization, etc

2.4 IMPROVE

A. Design of experiments (DOE)

1. Terminology
Define basic DOE terms, including independent and dependent variables, factors
And levels, response, treatment, error, etc. (Understand)
2. Design principles
Define and apply DOE principles, including power and sample size, balance,
Repetition, replication, order, efficiency, randomization, blocking, interaction,
Confounding, resolution, etc. (Apply)
3. Planning experiments
Plan, organize and evaluate experiments by determining the objective, selecting
Factors, responses and measurement methods, choosing the appropriate design,
etc. (Evaluate)
4. one-factor experiments
Design and conduct completely randomized, randomized block and Latin square
designs and evaluate their results. (Evaluate)
5. Two-level fractional factorial experiments
Design, analyze and interpret these types of experiments and describe how
confounding affects their use. (Evaluate)
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6. Full factorial experiments
Design, conduct and analyze full factorial experiments. (Evaluate)
B. Waste elimination
Select and apply tools and techniques for eliminating or preventing waste, including
pull systems, kanban, 5S, standard work, poka-yoke, etc. (Analyze)
C. Cycle-time reduction
Use various tools and techniques for reducing cycle time, including continuous flow,
single-minute exchange of die (SMED), etc. (Analyze)
D. Kaizen and kaizen blitz
Define and distinguish between these two methods and apply them in various
situations. (Apply)
D. Theory of constraints (TOC)
E. Define and describe this concept and its uses.
2.5 Control
A. Statistical process control (SPC)
1. Objectives
Define and describe the objectives of SPC, including monitoring and controlling
process performance, tracking trends, runs, etc., and reducing variation in a
process. (Understand)
2. Selection of variables
Identify and select critical characteristics for control chart monitoring. (Apply)
3. Rational subgrouping
Define and apply the principle of rational subgrouping. (Apply)
4. Control chart selection
Select and use the following control charts in various situations:
X¯ – R, X¯ – s, individual and moving range (ImR), p, np, c, u, short-run SPC and
moving average. (Apply)
5. Control chart analysis
Interpret control charts and distinguish between common and special causes
using rules for determining statistical control. (Analyze)

B. Other control tools

1. Total productive maintenance (TPM)
Define the elements of TPM and describe how it can be used to control the
improved process. (Understand)
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2. Visual factory
Define the elements of a visual factory and describe how they can help control
the improved process. (Understand)

2.6 Design for Six Sigma (DFSS) Frameworks and Methodologies

A. Common DFSS methodologies
Identify and describe these methodologies.
1. DMADV (define, measure, analyze, design and validate)
2. DMADOV (define, measure, analyze, design, optimize and validate)