Khóa học Lean Six Sigma Black Belt

Design for Six Sigma

1

• Welcome to Design for Six Sigma
• Closing the Gap
• Better Aim Through DFSS
• Improving Lifecycle Cost
• DFSS and DMAIC
• Introduction – What is DFSS?
• Development of DFSS
• Delimitation of Six Sigma and Design For Six Sigma
• Six Sigma and ICDOV cycle
• Phase model of DFSS
• Design Leverage
• DFSS from ICDOV
• DFSS Methodology
• DFSS tool box
• DFSS Achievements

Identify Phase

2

• Introduction – Identify phase
  • Definition
  • Organizational part
  • Product related part

• Objectives of Identify phase
• Activities and tools in Identify phase
  • Indentify activities flow
  • Project Selection Toolset
  • Project Charter Toolset
  • Project Tracking Toolset
  • Market Segmentation
  • Understanding Customer Requirements

• Listening to All the Voices
• Where to Go For Customer Requirements
• Affinity Diagram Toolset
• CTQC Tree Diagram Toolset
• Operational Definition Toolset
• Voice Of The Customer As Specifications
• Risk Rating
• Selected tools of identify phase
• Exercises

• Introduction – Concept phase
• Objectives of Concept phase
• Activities and tools in Concept phase
  • Concept activities flow
  • QFD Toolset
  • Metrics
  • The Core Principle of DFSS
  • Process Capability Toolset
  • Benchmarking

Concept Phase

5

• Beyond Customer Requirements
• Brainstorming
• Encouraging The Creative Process
• Narrowing Down The List of Ideas
• Pugh Concept Selection Toolset
• Exercises

Design Phase

6

• Introdution – Design phase
• Objectives of Design phase
• Activicies and tools in Design phase
  • Design Activities flow

• Design Development
• Results By Design
• Seleted tools of Design phase
  • Design score card
  • Analyzing Designs

Design Phase

7

• Effect chain analysis
• Morphological box
• TRIX
• DFMA
• Correlation and Regression Analysis
• Exercise

Design Phase

8

• Multiple Regression Toolset
• Error – proofing
• FMEA Toolset
• Product and Process Reliability
• Basic Reliability Calculation
• Transfer Function Toolset
• Exercises

Optimise Phase

9

• Introduction – Optimise phase
• Objectives of Optimise phase
• Activities and tools in Optimise phase
  • Optimise activities flow

• Building a Process Model
• From Process Diagram to Process Model
• Predicting Process Performance With Simulation
• Process Playground – Online Discrete Event Simulation

Optimise Phase

10

• Seleted tools of Optimise phase
  • P – diagram
  • Monte – Carlo simulation
  • Statistical
  • Tolerance Design & Optimization Toolset
  • Optimization with Response Surface Methods
  • Continuous Flow Optimization Toolset
  • Design For Lean – Supply Chain Dynamics
  • QFD: Building The Fourth House

• Exercises

Optimise Phase

11

• Introduction – Optimise phase
• Objectives of Optimise phase
• Activities and tools in Optimise phase
  • Optimise activities flow

• Building a Process Model
• From Process Diagram to Process Model
• Predicting Process Performance With Simulation
• Process Playground – Online Discrete Event Simulation

Optimise Phase

12

• Selected tools Of Optimise phase
  • P – diagram
  • Monte – Carlo simulation
  • Statistical
  • Tolerance Design & Optimization Toolset
  • Optimization with Response Surface Methods
  • Continuous Flow Optimization Toolset
  • Design For Lean – Supply Chain Dynamics
  • QFD: Building The Fourth House

• Exercises

Verify Phase

13

• Introduction – Verify phase
• Objectives of Verify phase
• Activities and tools in Verify phase
  • Verify activities flow

• Other Aspects of Verification
• The Process Control Plan
• Testing a Design
• Achieving Reliability Through Testing

Verify Phase

14

• Robust Design and Taguchi Methods
• Robustness Testing Practice
• Piloting a Design
• Launch
• The Lean Six Sigma Journey
• Exercises

Data and Lean Six Sigma

15

• Introduction to Data Analytics for Lean Six Sigma
• Data and DMAIC
• Units and operational definition
• Sampling
• Organizing your data
• Installing Minitab
• Introduction to Minitab
• Loading data into Minitab
• Practice quiz

Understanding and visualizing data

16

• Numerical and categorical data
• Descriptive statistics
• Visualizing numerical data
• Visualizing categorical data
• Graphical presetation
• Visualizing two variables
• Exercise - Investigation time
• Exercise - Coffee batch

Using probability distributions

17

• Population versus sampling
• Estimation and confidence intervals
• Normal, Lognormal and Weibull distribution
• Probability plot
• Empirical CDF
• Properties of the normal distribution
• Exercise - Length of Stay

Advance statistic: numerical Y and categorical X

18

• Introduction to data analysis
• Hypothesis testing
• Causality
• Introduction to ANOVA
• ANOVA analysis
• One way ANOVA
• Two way ANOVA
• MANOVA

Advance statistic: numerical Y and categorical X

19

• ANOVA residual analysis
• Kruskal-Wallis test
• One sample t-test Two sample t-test
• Pair t-test
• Z-test
• Test for equality of variances

Advance statistic: numerical Y and numerical Y

20

• Exercise — Productivity
• Exercise — Department
• Correlation
• Introduction to regression
• Regression analysis
• Regression residual analysis

Advance statistic: numerical Y and numerical Y and categorical Y

21

• Regression prediction interval
• Quadratic regression
• Exercise — picking
• Chi-square analysis
• Logistic regression
• Exercise — printers
• Exercise — production line

Advance statistic: Data distribution

22

• Normal probability distributions
  • Probability distributions
  • Normal distributions
  • Normal probabilities
• Non-normal probability distributions
  • Non-Normal Continuous Distributions
  • Non-Normal Discrete Distributions
  • Applying Data to Real-World Situations

Advance DMAIC: Define

23

• Creating a Project Charter
• Project advance tools
• Identifying organisational structures
• Using critical path project management tools (WBS, Gantt chart, Project Network Diagram)
• Establishing the critical path
• Managing time
• Business and Financial Issues
• Understanding the importance of a business case
• Developing a business case

Advance DMAIC: Define

24

• Identifying project costs
• Calculating return on investment (ROI)
• Calculating a payback period
• Determining net present value (NPV)
• Planning resources for your project team
• Managing your project team
• Managing conflict within your team
• Communicating effectively
• Define Toolset
• Define Tollgate Checklist
• Problem Functions: y = f(x)
• Process Mapping
• Advance Measurement Systems Analysis
• Data Collection and Summary

Advance DMAIC: Measure

25

• Process Capability
• Failure Modes and Effect Analysis
• Rolled Throughput Yield
• Collecting Data
• Critical to Quality Characteristics
• The COQ and the COPQ
• Quality is Critical to Success
• Measure Tollgate Checklist

Advance DMAIC: Analyze

26

• Correlation
• Linear Regression Analysis
• Using Correlation and Regression in Six Sigma
• A Review of Hypothesis Testing Errors
• What Information is Required for Choosing Sample Size?
• Sample Size Calculations: Choosing the Right Method
• Running and Analyzing Sample Size Tests in Minitab

Advance DMAIC: Analyze

27

• Graphical Analysis
• Statistical Analysis
• Scientific Method and P-Values
• Statistical Testing: Proportion Tests, Chi-Square
• Hypothesis Test Basics
• Selecting the Right Hypothesis Test
• Why Run Hypothesis Tests
• Running Hypothesis Tests
• Analyze Tollgate Checklist

Advance DMAIC: Analyze

28

• Preparing for a 1-Way ANOVA
• Running a 1-Way ANOVA
• Preparing for a 2-Way ANOVA
• Running a 2-Way ANOVA
• Preparing for a MANOVA
• Running a MANOVA
• Common Challenges When Presenting Statistical Analysis
• Analyze Tollgate Checklist

Advance DMAIC: Analyze

29

• Design of experiments
• Why Run an Experiment?
• Best-Guess Trial-and-Error versus Factorial Experiments
• What is Factorial Experimentation?
• Step-by-Step Guide for Creating a Designed Experiment
• Step-by-Step Guide to Running a 2k Factorial Experiment
• The Importance of Understanding Interactions
• 2k Factorials Versus Multi-Level Factorials
• Analyze Tollgate Checklist

Advance DMAIC: Improve

30

• Brainstorming and process improvement tools
• Activity Network Diagram
• Affinity Diagram
• Force Field Analysis
• Interrelationship Diagram
• Responsibility Chart
• Nominal Group Technique
• SWOT Analysis
• Starburst Brainstorming
• Role-Play or Figuring Brainstorming
• Brainwriting
• Brainstorming Alone

Advance DMAIC: Improve

31

• What is Value Stream Mapping?
• What Do You Do with Value Stream Maps?
• Tips for Creating a Future-State Value Stream Map
• Solutions Selection Matrix
• Cost Benefit Analysis
• Piloting a Solution
• Planning Implementation
• Capturing Improvement Data
• Improve Tollgate Checklist

Advance DMAIC: Analyze

32

• Create a Control Plan
• Visual Management
• SPC Charts
• Common Control Chart Types and When to Use Them
• Creating and Reading Control Charts in Minitab
• Team Celebration and Reflection
• Control Tollgate Checklist