By the end of this course delegates will be able to:

• Understand how Lean Methods and Six Sigma are integrated
• Relate Lean Six Sigma concepts to the overall business mission and objectives
• Communicate using Lean Six Sigma concepts
• Think about your organization as a collection of processes, with inputs that determine the output
• Recognize the organizational factors that are necessary groundwork for a successful process improvement program
• Use the concept of a Sigma Level to evaluate the capability of a process or organization

OE champions, Maintenance managers, engineers & planners, reliability and maintenance engineers, facilities and utilities managers, top level maintenance technicians, operations and production managers & engineers, plant engineers, design engineers, reliability engineers & technicians, operators, safety engineers, risk engineers, CMMS and spare parts personnel, safety engineers and anyone who is involved.

Introduction to Lean

• Lean Principles
• Lean Concepts
• The Six Production Losses
• The 7 Wastes and Others
• The Seven Process Wastes
• Looking for ‘Waste’ in Processes
• Benefits of Lean
• Monitoring Operating Effectiveness
• Production Losses and Overall Equipment Effectiveness
• Just-in-Time vs. Work-in-Progress
• Work-in-Progress Batch Inventory

The Critical Lean Concepts

• To Be Lean = Eliminate Non-Value
• Schedule to Match Takt Time
• Refine Your Value Adding Stream
• To Have Flow = Standardize & Level
• Benefit of Flow
• History of Value Stream Mapping
• The Value Stream Concept
• The Concept of Customer Value and Non-Value
• Discovering the Hidden Factory
• The Hidden Factory
• Another View of the ‘Hidden Factory’
• Straighten the Workflow
• Total Productive Maintenance
• The Operators’ Creed of TPM
• TPM Works by Reducing Risk of Failures
• Standards and Standardization
• Standardize the Work
• Developing Standardized Work
• 5S Creates a Visual Factory
• The 5S Cycle
• 5S Activities Explained

Lean Process Example

• Process Investigation
• Collecting Data from the Process
• The Current State Map
• Example of Current State Map
• Spotting Productivity Improvements
• Visualize Productivity Improvements
• Future State Map
• Future State Map
• Implementation Plan
• VSM Process

Introduction to Six Sigma

• What Six Sigma Means
• Defining What Good Performance
• Chance of Failure at Each Sigma Level
• Minimizing Variability
• What is Variation
• The Problems Start with Variation
• Causes of Variation

The Importance of Controlling Variation

• Where Profit is Lost in Business Processes
• Defects Cause Failure
• Failures Misuse Time and Resources
• The Best are Proactive
• Defect Elimination and Failure Prevention
• Problems are Variations Caused by Defects
• Stop Defects and you Stop Problems
• Reducing Variation with a Quality Systems
• The Purpose of a Quality Management System
• Planned Efforts to Remove Variation
• Applying 6 Sigma for Improvement

Applying Six Sigma

• Where Profit is Lost in Business Processes
• Why Organizations Lack Focus
• Roles in Six Sigma
• Six Sigma DMAIC process
• Six Sigma Project Life Cycle
• Problem Difficulty Distribution
• Defining Precision
• Human Error Rate
• Human Factors
• 12 Most Common Causes for Human Errors
• Apply Basic Statistical Control and Visual Management
• When Process Variability is Out-of-Control
• Process Quality Control Starts by Setting Outcome Limits
• Journey to 6 Sigma: Control Your Processes
• Move to ‘Preventive’ Quality Control
• 4 Pillars of Quality Management Systems

Introducing Lean Six Sigma into Organizations

• Elements of a Good Management System
• What Are the Critical Success Factors?
• Start Measuring Plant Non-Performance
• Getting high task reliability needs quality
• Understanding what it means to be ‘in control and capable’
• Accuracy Controlled Enterprise (ACE) Standard Operating Procedures Adds Statistical Process Control to Work Processes
• Remove variation, Accuracy Controlled Enterprise (ACE) Procedures
• The Accuracy Controlled Enterprise
• Accuracy Controlled SOPs Remove Variation with Proactive Statistical Process Control
• 7 Primary Quality Control Tools
• When to Apply the Quality Control Tools
• Pareto Chart the Problems for Focus

CDGA attendance certificate will be issued to all attendees completing minimum of 80% of the total course duration.