Introduction to Lean Methodology

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Overview

• Differences between Lean and Six Sigma Approach

• Focus of Lean Philosophy

• Lean Principles

  • Defining value

  • Mapping value stream

  • Creating flow

  • Establishing a pull system

  • Pursuing continuous improvement

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Lean Concepts and Tools

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• Muda (Waste)

• Mura (Unevenness)

• Muri (Overburdening)

• Heijunka (Levelling)

• Kaizen

• Kaikaku

• Kanban

• Poka yoke (mistakeproofing)

• Visual management

• 5S

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Introduction to Six Sigma

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• What is six sigma?

• History of six sigma

• Benefits of six sigma

• Six sigma project

• DMAIC Approach

• Roles and responsibilities

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Define Phase​

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Concepts and Tools

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• Y = f(Xn)

• SIPOC Analysis

• Voice of Customer

• Voice of Business

• Voice of Process

• Voice of Employee

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Deliverables

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• Assembling the project team

• Developing the project charter

• Performing SIPOC AnalysisPerforming VoC Analysis

• Defining CTQ

• Drafting the project objective

• Obtaining final approval for the project

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Measure Phase

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Introduction & Common Metrics

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• Defect

• Defective

• DPU

• DPMO

• Cycle time

• Takt time

• FTY

• FPY

• RTY

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Process Analysis

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• Definition of a process

• Process mapping

• Standard operating procedures

• Cause & effect diagram

• X – Y diagram

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Organizing Data

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• Data types

• Measures of central tendency

  • Mean

  • Median

  • Mode

• Measures of Dispersion

  • Range

  • Variance

  • Standard deviation

• Bar chart

• Pareto chart

• Line Graph

• Histogram

• Dot plot

• Box plot

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Six Sigma Statistics

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• What is Statistics

• Descriptive Statistics

• Inferential Statistics

• Sampling Techniques

• Parameter vs Statistic

• Types of Distribution

• Binomial Distribution

• Poisson Distribution

• Normal Distribution

• Exponential Distribution

• Chi Square Distribution

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Measurement Systems Analysis

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• Introduction

• Accuracy

• Precision

• Bias

• Linearity

• Stability

• Gage Repeatability & Reproducibility

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Process Capability

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• Introduction

• Specification Limits vs Control Limits

• Process Capability

• Process Capability Index

• Process Performance

• Process Performance Index

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Analyze Phase

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Analyzing and Interpreting Data

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• Introduction

• Basics of Hypothesis Testing

  • Null Hypothesis

  • Alternative Hypothesis

  • Confidence Interval

• Type I Error

• Type II Error

• Selecting the Sample Size

• P-Value

• Z Distribution

• T Distribution

• Correlation

• Causation

• 1 Sample Z Test

• 1 Sample T Test

• 1 Sample Proportion Test

• 1 Sample Variance Test

• 2 Sample Z Test

• 2 Sample T Test

• Paired T Test

• 2 Proportions Test

• 2 Variances Test

• ANOVA

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Interpreting Non-normal Data

• Kurtosis

• Skewness

• Bi-modal Distribution

• Rectangular Distribution

• Central Limit Theorem

• Non-parametric Tests

• Wilcoxon’s Signed Rank Test

• Mann-Whitney U Test

• Mood’s Median Test

• Kruskal-Wallis Test

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Regression & Residual Analysis

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• Simple Linear Regression

• Residual Analysis for Simple Linear Regression

• Multiple Linear Regression

• Residual Analysis for Multiple Linear Regression

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Improve Phase

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• Introduction to Improve Phase

• Identification of Possible Solutions

  • Brainstorming

  • Affinity Diagrams

  • Design of Experiments (DOE)

  • Benchmarking

  • Lean Tools

• Selection of the Best Solution

• Mapping the New Process

• Risk Analysis & Mitigation

• Pilot Test

• Evaluation of Pilot Test Results

• Full Scale Implementation

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Control Phase

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Statistical Process Control

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• Introduction

• Control Charts for Attribute Data

  • NP Chart

  • P Chart

  • C Chart

  • U Chart

• Control Charts for Continuous Data

  • Individual and Moving Range (I-MR) Chart

  • X Bar and R Chart

  • X Bar and S Chart

• Choosing the Appropriate Chart

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Institutionalizing the New Process

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• Standardizing the New Process

• Developing the Control Plan

• Cost-Benefit Analysis

• Recording the Lessons Learned

• Project Review