Lean Six Sigma & Operational Excellence

Introduction: 

Six Sigma is a data-driven approach for eliminating defects and waste in any business process. You can compare Six Sigma with turning your water faucet and experiencing the flow of clean, clear water. Reliable systems are in place to purify, treat, and pressure the water through the faucet. That is what Six Sigma does to business: it treats the processes in business so that they deliver their intended result.

What is “Sigma”? The word is a statistical term that measures how far a given process deviates from perfection. Sigma is a way to measure quality and performance. The central idea behind Six Sigma is that if you can measure how many “defects” you have in a process, you can systematically figure out how to eliminate them and get as close to “zero defects” as possible.

What is LEAN? Think about a lean person without extra fats, then compare that to business without losses in time, material, money, etc.

This workshop will give participants solid basic knowledge of the Lean Six Sigma methodology, and some of the tools required to deploy LSS in their own organizations and also pave the way for more knowledge.

Course Objectives:      

• Fully understand Lean Six Sigma and how it can be implemented in any organization.
• Identify the fundamentals of lean manufacturing, lean enterprise, and lean principles.
• Describe the key dimensions of quality – product/service features and freedom from deficiencies
• Understand how products and services that have the right features and are free from deficiencies can promote customer satisfaction and attract and retain new customers.
• Study and use the DMAIC process with more focus on Define, Measure, and Analysis steps.
• Discuss examples of poor-quality effects.
• Discover root causes of a problem
• Design and install new controls to hold the gains and to prevent the problem from returning.
• Develop future project for continuous improvement in the organization

Course Content:

The Building Blocks

• What is Six Sigma
• What is Lean
• Do we need lean six sigma?
• Roles in Six sigma
• The different belts
• Process and process related definitions
• Process Mapping methodologies
• KPIs: definitions – leading – lagging
• KPI development cycle

Waste!

• What is a waste?
• The 8 Wastes: defining wastes using DOWNTIME tool

DMAIC Overview

• Methodology and process steps
• Roadmap for DMAIC

Define Phase

• Project Charter and its contents
• Business case
• Who are my stakeholders?
• Voice of Customer – VOC
• Voice of Employee – VOE
• Creating a SIPOC

Measure Phase

• Selecting measures
• Data collection planning
• Essential Data analysis and visualization skills
• Baseline Data
• Interpreting Data
• Measure phase challenges
• Measure phase checklist
• Update Project Charter

Analyze Phase

• What is it?
• Process Analysis
• Rework Loops, Redundancies, and Bottle necks
• 5 Whys
• FMEA
• Ishikawa Diagram
• Pareto Analysis
• Analyze Phase challenges
• Check list for Analyze Phase

Improve Phase

• What is it?
• Creating flow
• Visual Management and 5S
• Improve Phase challenges
• Check list for improve phase

Control Phase

• What is it?
• Monitoring and response plan
• Documentation and Story board
• Control Phase Challenges
• Checklist for Control Phase

Other success factors in LSS projects – introduction (optional according to time utilization)

• Communication Skills
• Change Management

Target Audience:

All business professionals within a process driven or project environment and looking to understand how to use the tools and techniques for reducing errors, defects, waste and customer dissatisfaction.

Training Language:

• Materials in English. Delivery in English (Arabic optional)

No. of Participants:

• Designed for 15 people max.