IT 470a Six Sigma Green Belt

Transcription

1 IT 470a Six Sigma Green Belt Instructor: Mr. Tim Myers Visiting Instructor Southern Illinois University Carbondale Phone: (314) I. COURSE NUMBER AND TITLE: IT 470a Six Sigma Green Belt II. CREDIT HOURS: 3 credit hours III. PREREQUISITE: While there are no formal prerequisites for this course, the student is expected to have a good foundation in math, (application of algebraic formulas) statistical principles, and project management as well as critical thinking skills for objectively reviewing data to determine appropriate customer expectations. IV. DESCRIPTION OF COURSE: The course will be structured around classroom study as well as a project demonstrating proficiency in the application of Six Sigma tools and techniques. This class will encompass an overview of the Six Sigma methodology for reduction of variation in business and manufacturing process. V. TEXTBOOK: CSSGB PRIMER, Quality Council of Indiana, SUPPLEMENTAL READING: Statistics for Six Sigma Made Easy- Warren Brussee VI. COURSE OBJECTIVES: This course will provide the student with a comprehensive understanding of basics of Six Sigma Green Belt techniques and tools and their application. It will cover the knowledge areas of six sigma green belt. Topics include project scope and definition, DMAIC Problem-Solving methodology, Measures and Metrics, Statistical Methods, Control Charts, Design of Experiments, Reliability, and Failure Modes and Effects Analysis, Process Management, Team Dynamics, statistics and probability, measurement system analysis, and process capability. VII. INSTRUCTIONAL FORMAT: This is a weekend format two classes (Saturday and Sunday) for three alternating weekends. There will be classroom discussion with 3 exams and an applied project. The instructor will provide assistance and guidance as required.

2 VIII. EVALUATION:. Exam 1 (1 st Sunday) 15% Exam 2 (2 nd Sunday) 15% Exam 3 (3 rd Sunday) 15% Applied Project (Define and Measure Portion) 30% In class exercises and presentations 15% Homework 10% Textbook Material: Exams will be multiple-choice with approximately 30 questions selected directly from the text. Theses areas will be covered during in class discussions. The exams will account for 30% of the student s grade. Applied Project An applied project demonstrating the application of the Six Sigma tool set will account for 30% of the grade. In order to ensure that students have the necessary flexibility to complete their projects two options will be made available for students: Option 1 Complete an individual project. Option 2 Complete a project in a class group not to exceed 3 members. Project Guidelines It would be most beneficial if the project addresses a current workplace issue however due to the educational aspect of the project this is not a hard requirement. The best projects are data rich (i.e. have significant quantifiable data points) and have a limited scope due to the time constraints. Additionally, certain aspects of the project may be embellished due to the educational nature -- the intent is to apply the tools and understand the stakeholder s involvement in a real world application not to force a six sigma project on your employer. (The project will be started in 470a and completed in 470b) Homework Homework will consist of essays and presentations about a Six Sigma or lean topic and are designed to enhance your research and presentation skills. Subjects will be assigned during class. Presentations will be due the last weekend of the semester.. GRADING STANDARDS: A: % B: 80-89% C: 70-79% D: 60-69% F: <60% GRADING POLICY: Missed exams have a 20% penalty unless an appropriate, prior excuse is given to the instructor. The missed exam must be completed on the make-up date set by the instructor. ACADEMIC CONDUCT: Cheating on examinations, submitting work of other students as your own, or plagiarism in any form will result in penalties ranging from an F on the assignment to expulsion from the university, depending on the seriousness of the offense.

3 XII. : INSTRUCTOR AVAILABILITY: The best way to communicate with the instructor is by . The instructor is also available by phone if necessary. You may call me at home to discuss problems. Students are encouraged to discuss problems as they arise, before they become major problems out of control. The instructor will also periodically make his self available prior to or after class if you would prefer to meet face-to-face. Please try to schedule these sessions in advance.

4 MAJOR TOPICS: Six sigma goal Lean principles Theory of constraints (TOC) Design for six sigma (DFSS) Quality function deployment (QFD) Failure mode and effects analysis (FMEA) Process management Team dynamics Project management basics Data and process analysis Probability and statistics Measurement system analysis Process capability Project Guidelines: Define Identify Sponsor and other key stakeholders Identify the project team Team members Review process Clarify project Problem statement Goal statement Process output Define process boundaries SIPOC Define project boundaries Resources Scope Determine project timeline Identify CTQ Customer Requirements Define the Defect Define defect measure Gain Approval of Project Charter Develop Define report out Define Phase Project Report: Goal Statement Process definition (SIPOC) Project plan (Gantt chart) Customer Requirements (CTQs) Project Scope

5 Benefits assessment Next Steps and Help Needed Measure Understand detailed process Detailed process map w/ rework loops Create Fishbone Tie to defined defect Collect Data Ys (results) with Xs (data tags) Evaluate Measurement Systems Gage R&R, Attribute MSA Describe Process Numerical statistics Graphs: Time, Hist., Pareto, etc. Create control chart Establish Process Capability Calculate DPU, or FTY or P(d) Calculate Zst and Zlt Complete Control vs. Technology chart Update Charter Develop Measure report out Measure Phase Project Report: Detailed process map Data collection fishbone Measurement system analysis Process statistics and graphs Process performance and capability Project timeline and status (gantt chart) Next Steps and Help Needed Scorecard Analyze Analyze Process Flow Critical Path Value-added steps Non value-added steps Opportunities Analyze Data Graphical tools Hypothesis Tests Interrelationship Digraph (if approp.) Regression analysis

6 Conduct Root Cause Analysis Deep root cause identification on tree diagram Identify and collect additional required data Identify significant Xs Tie to root cause analysis Draw conclusions Update charter as required Develop Analyze report out and Brief Sponsor Analyze Phase Project Report: Updated project charter Process flow analysis Data analysis Root cause analysis Significant X identification Current Benefits Assessment Project timeline and status (gantt chart update) Next Steps and Help Needed Scorecard Improve Determine Levels of Response Develop solution options Improve control of significant root causes Re-design process to obtain required capability Perform DOE as required Evaluate options and select final solution Prioritization matrix Affinity Diagrams Determine measurement system for improved process Perform FMEA or Risk Assessment and develop Risk Abatement plan Create implementation plan Obtain buy-in / support for improvement actions Conduct pilot / testing to verify results Implement improvements Collect data to verify improvement Improve Phase Project Report: Current charter Solution options and evaluation results Description of solution and how it impacts the process Risk management plan or FMEA Implementation plan & methods to standardize new process. - Include measurement system for new process Pilot / test results

7 Full scale implementation results Benefits assessment Project timeline and status (gantt chart update) Next Steps and Help Needed Scorecard Control Perform Capability Analysis of improved process Control vs. Technology chart Develop and Implement a Control Plan Complete Project Closure Package Document Results List best practices Identify lessons learned Plan Celebration Communicate push leverage opportunities to applicable process owners Hand off project to process owner Create follow up action plan Develop Final report out Control Phase Project Report: Before / After Final Control vs. Technology chart Process control plan Project closure package Push leveraging opportunities Final Project Scorecard Project Summary Recognize why organizations use six sigma. Recognize key drivers for business and how key metrics and scorecards are developed. Describe the project selection process including knowing when to use six sigma improvement methodology (DMAIC). Define and describe lean concepts and tools such as value chain, flow, pull, kaizen, 5S, error-proofing, value-stream mapping, etc. Identify waste in terms of excess inventory, space, test inspection, rework, transportation, storage, etc. Describe the theory of constraints. Define and describe QFD. Use QFD to translate customer requirements into performance measures. Describe how QFD fits into the overall DFSS process. Define and describe FMEA. Describe the purpose and use of scale criteria and calculate the risk priority number.

8 Define and distinguish between design FMEA (DFMEA) and process FMEA (PFMEA) and interpret associated data. Describe and distinguish between DMADV (define, measure, analyze, design, verify) and IDOV (identify, design, optimize, verify), and identify how they relate to DMAIC. Define and describe process components and boundaries. Identify process owners, internal and external customers, and other stakeholders in a project. Define and describe the stages of team evolution. Describe and define the roles and responsibilities of participants on six sigma and other teams. Define and apply team tools such as brainstorming, nominal group technique, multivoting, etc. Use effective and appropriate communication techniques for different situations to overcome barriers to project success. Define and describe elements of a project charter and develop a problem statement. Assist with the development of project scope using Pareto charts, process maps, etc. Assist with the development of project metrics that relate to the voice of the customer. Use project tools such as Gantt charts, critical path method (CPM), and program evaluation and review technique (PERT) charts, etc. Use various methods to collect customer feedback Use graphical, statistical, and qualitative tools to analyze customer feedback. Develop and review process maps, written procedures, work instructions, flowcharts. Identify process input variables and process output variables (SIPOC), and document their relationships through cause and effect diagrams, relational matrices, etc. Distinguish between enumerative (descriptive) and analytical (inferential) studies. Distinguish between a population parameter and a sample statistics. Define the central limit theorem and describe its significance in the application of inferential statistics for confidence intervals, control charts, etc. Describe and apply basic probability concepts such as independence, mutually exclusive, multiplication rules, etc. Identify and classify continuous (variables) and discrete (attributes) data. Describe and define nominal, ordinal, interval, and ratio measurement scales. Define and apply techniques such as random sampling, stratified sampling, sample homogeneity, etc. Define, compute, and interpret measures of dispersion and central tendency. Construct and interpret frequency distributions and cumulative frequency distributions. Depict relationships by constructing, applying and interpreting diagrams and charts such as stem-and-leaf plots, box-and-whisker plots, run charts, scatter diagrams, Pareto charts, etc. Depict distributions by constructing, applying and interpreting diagrams such as histograms, normal probability plots, etc. Describe and interpret normal, binomial, and Poisson, Chi Square, Student s t, and F distributions.

9 Calculate, analyze, and interpret measurement system capability using repeatability and reproducibility, measurement correlation, bias, linearity, percent agreement, and precision/tolerance. Identify, describe, and apply the elements of designing and conducting process capability studies. Distinguish between natural process limits and specification limits. Calculate process performance metrics such as percent defect. Define, select, and calculate Cp and Cpk, and assess process capability. Define, select, and calculate Pp, Ppk, Cpm, and assess process performance. Compute the sigma level for a process and describe its relationship to Ppk.