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| Section | Objectives |
|---|---|
| Lean Process Improvement | - Toyota Production System, seven wastes - PDSA cycle, R-DMAIC-S model - Lean thinking tools and Kaizen events |
| Organizational Roadblocks and Lean Management | - Organizational roadblocks and resistance analysis - Overview of continuous improvement, Lean and Six Sigma - Lean tools: 5S, Kaizen, SMED, Heijunka - Lean concepts: TAKT Time, Cycle Time, PCE, Lead Time, SWIP, Setup/Changeover time |
| Define Phase | - Project charter, team dynamics, facilitation - SIPOC/COPIS mapping - Kano Model, Quality Function Deployment - VOC/VOB/VOP, CTQ/CTC/CTS, CTQ tree - Baseline performance, Rolled Throughput Yield, Six Sigma statistical definition |
| Control Phase | - Taguchi's Loss Function - Control plan, project closure, TPM introduction - Variable and attribute control charts |
| Measure Phase | - Graphical analysis, normality testing, Weibull distribution - Measurement Systems Analysis: Gage R&R, stability, capability (Cp, Cpk, Cpkm) - Data types, scales, distributions, central tendency, dispersion |
| Improve Phase | - Design of Experiments: principles, full/fractional factorial, response surface - Cost-benefit analysis, solution prioritization, Pugh Matrix |
| Pre-Define Phase | - DMAIC vs DFSS - Project prerequisites and prioritization matrix - Financial metrics: NPV, IRR - Enterprise vs line-of-business perspective |
| Analyze Phase | - Parametric and non-parametric hypothesis testing - Common vs special cause variation - Simple, multiple and curvilinear regression - Root cause tools: Fishbone, Pareto |
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