Program Content

Part 1: Lean Thinking

• Lean philosophy, history, and background
• Lean and the Theory of Constraints
• The Lean Roadmap
• Customer value add analysis
• Business value add and non-value add
• The 8 types of waste
• Practical simulation, part 1
• Value stream mapping
• Flow
• Line balancing and Takt time
• Pull and Little’s law
• Kanban, safety stock, and replenishment pull
• Practical simulation, part 2
• Poka Yoke
• 5S and Visual Management
• SMED and setup reduction
• 5 time Why

Part 2 : Six Sigma

Module 1 Introduction

• Background of Six Sigma
• The Six Sigma organization
• The DMAIC improvement structure
• Using Six Sigma for transactional processes
• Implementation of Six Sigma

Module 2 Define

• The role and importance of the DEFINE stage
• The Voice of the Customer
• The CTQ project
• Compiling a Six Sigma project team
• The Six Sigma project charter
• KANO Model
• The path to CTQs
• Project selection
• SIPOC
• Stakeholders diagram

Module 3 Measure

• Determining project Y
• Data types
• Data collection plan
• Baseline performance
• Measuring system
• Determining the improvement goal
• Process capability

Module 4 Basic statistics

• What is statistics?
• Basic concepts
• Histogram and normal distributions

Module 5 & 6 Analysis

• Possible root causes
• Prioritizing causes
• Graphical analysis techniques
• Causes and consequences
• FMEA

Module 7 Improve

• Generating solutions
• Trial Experiments
• Techniques for generating ideas
• Selecting the best solution
• Conducting pilots

Module 8 Control

• Control plan and control mechanisms
• Implementing and confirming the solution
• Project documentation
• Project closing

Program claimable under HRD Corporation