Yellow Belt Body of Knowledge
 Introduction to Lean Methodology
  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

​  Lean Concepts and Tools

  • Muda (Waste)

  • Mura (Unevenness)

  • Muri (Overburdening)

  • Heijunka (Levelling)

  • Kaizen

  • Kaikaku

  • Kanban

  • Poka yoke (mistakeproofing)

  • Visual management

  • 5S

Introduction to Six Sigma
   Overview
  • What is six sigma?

  • History of six sigma

  • Benefits of six sigma

  • Six sigma project

  • DMAIC Approach

  • Roles and responsibilities

Define Phase
   Concepts and Tools
  • Y = f(Xn)

  • SIPOC Analysis

  • Voice of Customer

  • Voice of Business

  • Voice of Process

  • Voice of Employee

   Deliverables
  • Assembling the project team

  • Developing the project charter

  • Performing SIPOC Analysis

  • Performing VoC Analysis

  • Defining CTQ

  • Drafting the project objective

  • Obtaining final approval for the project

Measure Phase
   Introduction & Common Metrics
  • Defect

  • Defective

  • DPU

  • DPMO

  • Cycle time

  • Takt time

  • FTY

  • FPY

  • RTY

   Process Analysis
  • Definition of a process

  • Process mapping

  • Standard operating procedures

  • Cause & effect diagram

  • X – Y diagram

   Organizing Data
  • 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

   Six Sigma Statistics
  • What is Statistics

  • Descriptive Statistics

  • Inferential Statistics

  • Sampling Techniques

  • Parameter vs Statistic

  • Normal Distribution

   Measurement Systems Analysis
  • Introduction

  • Accuracy

  • Precision

  • Bias

  • Linearity

  • Stability

  • Gage Repeatability & Reproducibility

   Process Capability
  • Introduction

  • Specification Limits vs Control Limits

  • Process Capability

  • Process Capability Index

  • Process Performance

  • Process Performance Index

Analyze Phase
Analyzing and Interpreting Data
  • Introduction

  • Discrete Distribution

  • Continuous Distribution

  • Basics of Hypothesis Testing

    • Null Hypothesis

    • Alternative Hypothesis

    • Confidence Interval

  • Type I Error

  • Type II Error

  • Correlation

  • Causation

  • Failure Mode & Effect Analysis (FMEA)

Improve Phase
  • 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

Control Phase
  Statistical Process Control
  • 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

   Institutionalizing the New Process
  • Standardizing the New Process

  • Developing the Control Plan

  • Cost-Benefit Analysis

  • Recording the Lessons Learned

  • Project Review