Day 1:
Fundamentals of Lean Six Sigma
Overview of Lean and Six Sigma: History, evolution, and complementary strengths.
Introduction to DMAIC (Define, Measure, Analyze, Improve, Control) framework.
The 8 Wastes (DOWNTIME) and their impact on organizational performance.
Case study: Identifying waste in a service-oriented process.
Day 2:
Tools and Techniques for Process Improvement
Process mapping: SIPOC diagrams and value stream analysis.
Data collection methods and basic statistical metrics (mean, median, standard deviation).
Root cause analysis: 5 Whys and Fishbone diagrams.
Workshop: Applying tools to a simulated manufacturing process.
Day 3:
DMAIC Phases – Define & Measure
Project selection: Aligning improvement initiatives with strategic goals.
Stakeholder analysis and Voice of the Customer (VoC) integration.
Measurement system analysis (MSA) and process capability indices (Cp, Cpk).
Group exercise: Developing a project charter for a real-world scenario.
Day 4:
DMAIC Phases – Analyze & Improve
Hypothesis testing and basic statistical inference (t-tests, chi-square).
Solution prioritization using cost-benefit analysis and FMEA.
Pilot testing and change management strategies.
Simulation: Implementing improvements in a healthcare case study.
Day 5:
Control Phase & Certification Preparation
Designing control plans: Standard work, visual management, and SPC charts.
Sustaining improvements through Lean Six Sigma governance.
Review of certification exam structure and practice questions.
Final assessment: Participants present a process improvement project proposal.
