[Fusion White Paper]

Fusion Training

Fusion is a new training system developed by PROMAX’s Lean Six Sigma Division that brings together Lean Six Sigma Black Belt, Green Belt and Champion/Sponsor training into one comprehensive, integrated course of study.  

Duration: 3-4 days consulting on project selection, and 4 - one week training sessions (each three weeks apart)

Course Content:  first  Week

·                   Lean Six Sigma, History of Quality, Strategy and Principles

·                   Roles & responsibilities

·                   DMAIC and DMADV Process Overview

·                   Available Lean Six Sigma Training

·                   Deployment Plan

·                   Policy Deployment

·                   Strategic Planning-Deploying Projects

·                   System of Indicators– Key Performance Indicators, Balanced Scorecard, Flag System of Indicators

·                   Define COPQ– Hidden Cost, Internal Failure Cost, Cost of Field Failures, Cost of Inspection, Cost of Prevention

·                   Introduction to Lean Lean Six Sigma Tools- Value Stream Mapping , Types of Data, Data Collection, Measurement System Analysis, Process Capability, Descriptive Statistics, Hypothesis Testing, ANOVA, Design of Experiments, Lean Enterprise, SPC, FMEA, Weibull Analysis

·                   Voice of the Customer – Customer CTQ’s, Sources of VOC, Dimensions of Quality the Kano Model, VOC Process Planning

·                   Project Selection  

·                   Management Reviews – Definition and Purpose, How to Conduct a review and Guidelines for Management

Formal Champion Training is completed on the third day -- Ends Here

·                   Define– Indicators, Problem Definition, Project Charter, Project Planning Worksheet

·                   Process Management – Definition of Core, Macro Micro/Enabling, Select Top Priority Process, Process Flowcharting – construct flowchart of identified process, selecting Process Indicators

·                   Measure – Purpose of Data, Types of Data

·                    Basic Sampling - Simple Random Sampling, Systematic Sampling

·                    Data Collection – Principles of Data Collection, Sources of Data, How to design a Checksheet

·                   Displaying Data – Histograms, Frequency Charts, Line Graphs, Run Charts, Bar Charts, Radar Charts

·                   Project Planning – Status, Action Planning

Course Content:  second   Week

·                   Analyze – Logic of Root Cause Analysis

·                   Basic Probability & Statistics – Descriptive vs. Inferential Statistics, Measures of Central Tendency, Measures of Dispersion, Basic Probability

·                   Stratification – Pareto Charts

·                   Cause/Effect Analysis – Potential Root Causes, Cause & Effect Diagram, Root Cause Verification

·                   Improve and Implement – Identifying Countermeasures, Cost/Benefit Analysis, Force Field Analysis, Develop Implementation Plan, Confirm Results

·                   DFSS / DMEDVI – Define-Measure-Evaluate Design Concepts-Develop Final Design – Validate Design – Implement Design

·                   Control – Control of Processes/Products –Standardize – Standard Operating Procedures, Eliminate Variation , Control Charts

·                   Introduction to Statistical Process Control – Understanding Variation, Types of Variation, Sources of Variation, Control Chart Definitions, Control Chart Components, How to use Control Charts, Interpreting Control Charts

·                   Variables Control Charts – X bar R Chart, X, mR Chart

·                   Attribute Control Charts – np Chart, p Chart, c Chart, u Chart, How to select the proper control chart  

·                   Lean Enterprise – Principles for a Lean Enterprise

·                   Components of Lean – Operations Layout and Balancing, Design for Production, Mistake Proofing, Batch Size Reduction, Customer Demand Pull The Value Stream Map

·                   Waste Elimination

·                   8 Sources of Waste

·                   Continuous One-Piece Workflow

·                   Demand Pull Processing

·                   Kan Ban

·                   5 S’s  - Sort, Store, Shine, Standardize, Sustain

·                   Mistake Proofing

·                   Plan to Mitigate Top Priority Risks – Identify actions to attack risks – develop action plan, estimate post seriousness after mitigation, estimate Post-Probability of Occurrence – Calculate Post-Risk Prioritization Number.

  Formal Green Belt Training is completed at the end of the 2nd Week - Ends here

Course Content:  Third   Week

·                   Advanced Probability and Statistics – Review of Descriptive Statistics

·                   Introduction to Minitab – Worksheet and Project File Structure, Session Window, Using Minitab Worksheets, Manipulating Data with Minitab

·                   Characteristics of the Normal Curve – Chebyshev’s Theorem, Calculating Percentiles.

·                   Standard Normal Transformation

·                   Probability Definitions- Permutations and Combinations, Laws of Probability

·                   Advanced Sampling –Sampling Rules of Thumb, Sampling Definitions, Sample Size Formulas, Sampling Error, Significance Level.

·                   Other Sampling Techniques-Two-Stage Sampling, Stratified Sampling, Cluster Sampling, Confidence Intervals.

·                   Measurement Systems Analysis-Measurement System Components, Sources of Observed Variation, How to Conduct MSA Studies, Attribute MSA, Variables MSA.

·                   Process Capability- Control Limits vs. Customer Specifications, Loss Function Concept, Process Capability Indices, Shifts and Drifts (1.5 Sigma Shift).

·                   Calculating Process Yield

·                   Comparing Stability and Capability

·                   Hypothesis Testing- Detecting Differences, The Null Hypothesis, The Alternate Hypothesis, Visualizing Risks, Hypothesis Testing Procedure, Hypothesis Testing Decision Tree, Test of Means-Variance Known, Test of Means- Variance Unknown, Test of Variances vs. Standard, Test of Two Population Variances, Test of Proportions vs. Standard, Test of Two Population Proportions

·                   Non Parametric Tests of Hypothesis -Test for Normality, Tests of Medians, Test of Two Population Medians, Test of Multiple Medians

·                   Correlation/Regression Analysis

·                   ANOVA – Test of Multiple Means, Analysis of Means

·                   Introduction to Design of Experiments – One factor at a time experiments, DOE Process, DOE Planning, DOE Applications

·                   DOE Activity Instructions

·                   Build DOE Model – Test and Modify DOE Model, DOE Catapult Competition

Course Content:  Fourth   Week

·                   Benchmarking -   Reasons for Benchmarking , Types of Benchmarking, Basic Benchmarking Methodology, Preparing for Benchmarking, Benchmarking Ethics

·                   Reliability – Basic Reliability Methods,  Reliability Management

·                   Fault Tree Analysis – Causes of Undesirable Events, Fault Tree Terms and Symbols, Fault Tree Diagram, Quantifying the Fault Tree

·                   Quantifying Reliability - Measures of Reliability, Data Components, Goals of Reliability Data Analysis, Censored Data, Life Data Models, Calculating Mean Time Between Failures

·                   Weibull Analysis – Calculating Failure Rate, The Bathtub Curve, Weibull Distribution, Failure Data Analysis

·                   Failure Modes and Effects Analysis (FMEA) – Identify Failure Modes and Effects, Assess Seriousness, Identify Potential Causes, Estimate probability, Identify Detect ability, Measure Controls – Calculate Risk Prioritization Number  

·                   Management and Planning Tools –7 New Management & Planning Tools – Relationship Diagram, Affinity Diagram, Systematic Diagram, Matrix Diagram, Matrix Data Analysis, Arrow Diagram, Process Decision Program Chart

Green Belt and Black Belt Recap

·                   Project Presentations - Champions Review

·                   Celebration

Course Materials:

·                   Course Manuals

·                   Certified Six Sigma Black Belt Primer

·                   Six Sigma Pocket Guide

·                   Minitab 14 Software for Black Belts Only