What is Six Sigma?
Six Sigma is a rigorous and disciplined methodology that uses data and
statistical analysis to measure and improve a company's operational
performance by identifying and eliminating "defects" in
manufacturing and service-related processes. Commonly defined as 3.4 defects
per million opportunities, Six Sigma can be defined and understood at three
distinct levels: metric, methodology and philosophy...
Six Sigma is a customer focused, data
driven methodology for achieving real break through success in business. Six
Sigma is a comprehensive and flexible system and can be applied to reduce
defects, improve designs and process efficiencies. To
learn more about Six Sigma, please click here.
Why
3Sigma is not enough?
(Is
99.73% (= 3Sigma Performance Level)
Really Good Enough?)
Even a three Sigma level company is not good enough, because a 3Sigma
level performance means,
* 200,00 lost articles of mail per hour.
* No electricity for almost 7 hours, each month.
* 2 short or long landings at major airports, each day.
* 200,000 wrong drug prescriptions each year.
* Unsafe drinking water almost 15 minutes each day.
* 5000 wrong surgical operations per week.
(The above information is based on a survey conducted in US)
Now, can
anyone afford to stop at 3Sigma level performance? If a company performs even
at 3Sigma level, (that is 99.73% result fall with in the control limits) the
above defects are possible. Because of the above cited huge loses, generally
many companies go for Six Sigma Implementation Programs/Certification.
Why you need to do Six Sigma?
Six Sigma can cut
waste and save money. Consider how much money could be saved by eliminating
potential defects and the resulting scrap and warranty returns. Time and
money may be wasted in corrective actions and delays. Also consider the image
those results from product failures for the customer. In order to determine
the waste, you need to understand what adds value to your product and what
does not.
One way to
know how good you are doing is to compare your operation to similar ones
elsewhere, as a benchmark. If there are similar operations in your
organization, then bench marking will be easier.
Lean Six
Sigma Costs and Savings
One can't expect to significantly reduce costs and increase sales using Six
Sigma without investing in training, organizational infrastructure and
culture evolution. Sure you can reduce costs and increase sales in a
localized area of a business using the Six Sigma quality methodology. For
Example,
* Motorola adopted Six Sigma in1987. In 1988, Motorola won its first
Baldridge Award.
"Companies of all types and sizes are in the midst of a quality
revolution. GE saved $12 billion over five years and added $1 to its earnings
per share. Honeywell (AlliedSignal) recorded more than $800 million in
savings."
"GE produces annual benefits of over $2.5 billion across the
organization from Six Sigma."
"Motorola reduced manufacturing costs by $1.4 billion from
1987-1994."
"Lean Six Sigma reportedly saved Motorola $15 billion over the last 11
years."
Who should attend?
CEOs, Presidents, Project Managers, Team leaders/Members, Field Staff
Members, Project Engineers, Design Engineers, Project Leaders and
Administrators, Industrial Engineers, Program Managers, Manufacturing
Engineers, Project Coordinators, Operating Managers, Functional Managers,
Information Technology Professionals, Software Developers, Quality &
Testing Engineers, Sales & Marketing professionals,
Civil/Mechanical/Electrical engineers, Procurement specialists, Event
mangers, R&D Managers, others involved directly or indirectly with
Project Management, Quality assurance managers, BPO team leaders, and
Executive leadership from Finance, Training, Communications, Human Resources
and Quality who are interested in gaining a better understanding of
manufacturing processes and reducing process variability in order to improve
business success. This includes:
* Individuals who desire to enhance their professional
development with the skills necessary to support Six Sigma projects.
* Employees of companies that have deployed Six Sigma,
who work with Black Belts, or who lead their own improvement projects.
Companies that want to expand training across a wide range of employees to
reduce costs and improve performance
Course Structure (Online):
This Six Sigma Green Belt course
is a PMI approved web-based self-study course with access to the participants
to the online resources for 3-6 months including the green belt project
completion time. The course is supplied with an end of the course
evaluation test of what was learnt and the participants will be supported
with Excel templates where ever required.
All online
participants who are PMPs will earn 40 PDUs Certificate towards their CCR
once they have completed 40 hours of online study through this PMI approved
PDU course. Sample PDUs
Certificate. Click Here
All
online participants can also download a full Green Belt editable project template for their use.
Course Structure (Classroom):
This Six Sigma Green Belt course
is a PMI approved Classroom study.
All classroom
participants who are PMPs will earn 40 PDUs Certificate towards their CCR on
the 4'th day through this PMI approved PDU course.
All
classroom participants will be given a CD of full Green Belt editable project template for their use. The CD contains
DMAIC stages, simple explanations, some situational case studies, useful
templates and Statistics Software. This software useful to calculate sigma
levels and to draw Excel charts.
·
Control
Chart
·
Creating
Control Charts Using Microsoft Excel
·
Editable
Project Charter
·
Editable
Sipoc Diagram
·
Project
selection
·
QI-Statistics
Software
·
Sample
Size Calculator
·
Sigma
Conversion Table
·
Six
Sigma Sample Questions
·
Six
Sigma Sample Project Report
Date:
·
16, 17, 18, 19 May' 09
Course fee for
Lean Six Sigma Green Belt Certification -
CLASS ROOM:
* Green Belt Certificate
Only - Special offer fee Rs.
15,000 + 10.3%
service tax only (for general professionals)
* Green Belt Certificate + 40 PDUs
Certificate - Rs. 19,000 + 10.3% service tax only
(optional item for PMPs only)
Course fee for online
participants:
* Green Belt Certificate
Only - Special offer fee US
$ 340 only (for
general professionals)
* Green Belt Certificate + 40 PDUs
Certificate - US $ 400 only (optional item for PMPs
only)
Lean
SIX SIGMA Green Belt Sample Certificate.
Click Here
Sample
PDUs Certificate. Click Here
PDUs
Offered:
Earn 40 PDUs
(PMI
Approved) - Click here to see PMI Approval.
Course Completion Exam:
A 100 questions based test
to measure the knowledge gained by the participants and to demonstrate the added
confidence level out of this course.
GB
Project Details:
GB
Projects:
Please note that the projects for improvement can be from your own company
(or) any other company. The projects can address the entire company are small
portion (or) part (or) division (or) a small process of a business unit with
in the company. The candidates can also suggest project titles from
their company for the faculty / instructors / suggestions (or) they can
choose any one of the projects available at IIPM. IIPM will facilitate the
collection of data and extend support staff services for the project
period.
Lean
Six Sigma Projects Guided by
IIPM:
1. Case management in Microsoft,
Sutherland
A Case study
-
BPO Industry.
2. Reducing Turn Around Time
(TAT) of Production Support Request in Cambridge Solution
A Case study -
Manufacturing
Industry.
3. Reduction of OLA Deviation in
CVS processing in SIFY
A Case study
-
Software Industry.
4. Reduction in Manufacturing of Flanges Production Turn
Around Time (TAT)-A Case study-Construction
/ Fabrication Industry.
Some example projects are below.
Project 1) Registration
process improvement.
Project 2) Defects
and improvements in Training.
Project 3) Defects
and improvement in online training .
Project 4) customer
Call registration Improvement.
Project 5) Training
course-ware quality improvement.
Project 6) Admin
and maintenance expenses improvement.
Project 7)
MARKETING EXPENSES IMPROVEMENT: RETURN ON INVESTMENT (ROI).
The
participants can identify projects in their own organization and implement
the DMAIC methodology and show significant improvement in organization. The
Students shall review the projects with IIPM on monthly basis. Any questions
clarifications can be discussed during the review. Sample project also available for all
Online/Classroom registered participants.
Lean SIX SIGMA Green Belt Certificate:
This Green Belt
certificate will be awarded to all those who have completed the course by
passing a test at the end of the course. Please note those sample/model
practice questions are available for participants. However Green Belt project
completion certificate will be awarded if one has finished / implemented Six
Sigma Projects in his/her organization and
shows significant improvement in the process chosen for improvement.
Lean SIX SIGMA Green Belt Sample
Certificate.
Click Here
Sample
PDUs Certificate. Click Here
This 40 hours PDU certificate will be awarded those who
have finished 40 hours of study from this course.
Templates:
Useable, practical templates and
tools are downloadable in our Six Sigma course. These templates are editable
and can be modified to suit your companys requirements.
Lean SIX SIGMA GREEN BELT
CLASS ROOM COURSE CONTENTS
Click Here to download the
Classroom Course Contents
1. Introduction
Introduction to Six Sigma
History of Six Sigma
How to work Six Sigma
Goals and Objectives
Benefits of Six Sigma
What is Quality
Gaps in Service
Achieving Six Sigma quality
Voice Of Customer
2. Basic Statistics
Introduction
Mean, Median, Mode
Variance, SD
Process Capability
Voice of customer
Six Sigma Data Type's
Normal Distribution
Organizational Structure and Roles
COPQ (Cost Of Poor Quality)
3. Six Sigma Methodologies
DMAIC
DMADV
Six Sigma metrics
DPU & DPMO
Yield Computations
Hidden Factory
How to calculate Sigma level
4. DEFINE Stage
Introduction to DEFINE Phase
Objectives
Project Charter
Introduction SIPOC
Create SIPOC
Sample SIPOC
Flow Chart
Process map
Top level Process definition
KANOs model
Quality Function Deployment
Affinity Diagram
5. MEASURE Stage
Introduction to MEASURE Phase
Objectives
Why MEASURE phase needed
Key Performance Indicators (KPI)
Metric definition
CTS,CTQ,CTP Explained
Measurement System Analysis
Precision versus Accuracy
Sampling methods
Process Capability
Value-added Non-Value-added activities
6. ANALYZE Stage
Introduction to ANALYZE Phase
Objectives
Failure Modes and Effects Analysis
Value Stream Analysis
Analyzing Sources of Variation
Exploratory Data Analysis (EDA)
Data Mining
Check sheet
Run Chart
Pareto Analysis
Scatter diagram
Cause and effect diagram
Control charts
Box-Plot-Components
Hypothesis Testing
Risk
7. IMPROVE Stage
Introduction to IMPROVE Phase
Objectives
Defining the New Processes
Lateral Thinking
Brainstorming
Benchmarking
Five-S
Mistake Proofing
Design of Experiments (DOE)
Implementation and Verification
8. CONTROL Stage
Introduction about CONTROL Phase
Objectives
Standardize on the New Methods
Measure Bottom line Impact
Standard Operating Procedure
Process audit system
9. Control Charts
I-MR charts (Moving range,
Individuals)
X bar R charts
X bar S charts
Np Chart
P Chart
C Chart
U Chart
10. Introduction to DMADV
Introduction
Design for Six Sigma
Lean Six Sigma
11. Conclusion
Purpose and guidelines of DMAIC
Checklist for DMAIC
Dos and Donts to DMAIC
12. Class Room Exercises
13. Case Study
14. Final Six Sigma Exam Open book / Group Test
15. Six Sigma CD Demo
16. Certificate Distribution
17. General Q&A
For
Online Course Registration
For Classroom Course Registration
