[learn six sigma green belt for beginners in a nutshell

7/26/2019 [Learn Six Sigma Green Belt for Beginners in a Nutshell

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Six Sigma

Green Belt


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Introduction

I. Six Sigma Green Belt Program


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Introduction

to Six Sigma

1. What is Six Sigma?

2. Evolution of Six Sigma


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What is

Six Sigma

1. Method to achieve defect level of 3.4 PPM

2. Method to achieve breakthrough improvements

(10X or 10 times improvements in terms of Cost,

Quality and Delivery)


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In 1980 ,Motorola -Survival problem - with fierce

Japanese competition

CEO Bob Gelvin determined not to loose parental

company Motorola !!

Evolution of Six Sigma

-

Motorola


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Evolution of Six Sigma

-

Motorola

Bill Smith gave a solution reduce defects from

30,000 ppm to 3 ppm (in 8 years )

Goal of 68 % improvements for every employee

every year in all units of Motorola ( for 10 fold

improvements every 2 years )


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Evolution of Six Sigma - Motorola

Actions taken at Motorola

Strong emphasis on training with 300 million $

budget ( Return was 800 million $ within 2 years)

Global Benchmarking


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CEO Jack Welch (in 1995 ) had goal of 10 fold

improvements within a year

Six Sigma was adopted as Philosophy

Evolution of Six Sigma - GE


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A structured Approach to continuous Improvement

A Philosophy

A Statistical Measurement

A Metric

A Business Strategy

A measuring system

Make fewer mistakes in all

we do

Helps gauge adequacy of

product, process and services

Good quality reduces cost

What is Six Sigma?


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20,000 lost articles of mail per hour

Unsafe drinking water almost 15

minutes each day

5,000 incorrect surgical operations per

week

2 short or long landings at most major

airports daily

200,000 wrong drug prescriptions each

year

No electricity for almost 7 hours each

month

Seven lost articles of mail per hour

One minute of unsafe drinking water

every seven months

1.7 incorrect surgical operations per

week

One short or long landing at most

major airports every five years

68 wrong drug prescriptions each

year

One hour without electricity every 34

years

Power Of Six Sigma

Introduction to Six Sigma?

The Classical View of Quality

99% Good (3.8s)

The Six Sigma View of Quality

99.99966% Good (6s)


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Introduction to Six Sigma?

One sigma

Two sigmaThree sigma

Four sigma

Five sigma

Six sigma

170 misspelled words per page in a book

25 misspelled words per page in a book

1.5 misspelled words per page in a book

1 misspelled word in 30 pages (about one chapter)

1 misspelled word in a set of encyclopedias

1 misspelled word in all the books in a small library

-

-

-

-

-

-

Sigma Spelling

A Practical Example

Three Sigma = 93.32% Four Sigma = 99.38% Six Sigma = 99.99966%


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Key Role ResponsibilitiesChampions

Sponsors

Sponsors the project

Business process owner

Primary responsibility is to remove road block for team from achieving the goal

Responsible for making major decisions during the improve stage

Master Black

Belts

Full time member of the team

Responsible for providing detail technical consultation internally, if necessary

Six sigma content professor

Black Belts Full time member of the continues improvement / quality team Responsible for leading the management of the team and project

Official content owner

Green Belts User of the process(es) and functional organization being improved Responsibilities are identical to those of a black belt but maintains a full time

position in the functional departmentDeployment Team Individual members responsible for executing specific tasks

Usually gets selected based on technical background and closeness of his/her

position to the identified quality process.

Roles in Six Sigma Journey


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ASQ Certification


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ASQ Certification

1. Six Sigma Green Belt Certification - CSSGB

2. ASQ Certification Requirements

3. ASQ Body of Knowledge


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Certification is formal recognition by ASQ that an individual has

proficiency within, and a comprehension of, a specified body of

knowledge.

1. Each certification candidate is required to pass a written

examination that consists of multiple choice questions that

measure comprehension of the Body of Knowledge.

2. The Six Sigma Green Belt Certification is a four-hour, 100 multiple-

choice question examination.

3. Examinations are conducted twice a year, in June and December, by

local ASQ sections and international organizations.

4. All examinations are open-book. Each participant must bring his or

her own reference materials.

Six Sigma Green Belt Certification


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The Six Sigma Green Belt requires three years of work

experience in one or more areas of the Six Sigma

Green Belt Body of Knowledge.

Certification Requirements


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I. Overview: Six Sigma and the Organization (15 Questions)a) Six sigma and organizational goals

b) Lean principles in the organization

c) Design for Six Sigma (DFSS) in the organization

II. Six Sigma Define (25 Questions)

a) Process Management for Projects

b) Project management basics

c) Management and planning tools

d) Business results for projects

e) Team dynamics and performance

ASQ Body of Knowledge


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III. Six Sigma Measure (30 Questions)a) Process analysis and documentation

b) Probability and statistics

c) Collecting and summarizing data

d) Probability distributions

e) Measurement system analysis

f) Process capability and performance

IV. Six Sigma Analyze (15 Questions)

a) Exploratory data analysis

b) Hypothesis testing

V. Six Sigma Improve & Control (15 Questions)a) Design of experiments (DOE)

b) Statistical process control (SPC)

c) Implement and validate solutions

d) Control plan

ASQ Body of Knowledge


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I. Overview: Six Sigma and the Organization (15 Questions)

a)Six sigma and organizational goalsi. Value of six sigma

ii. Organizational drivers and metrics

iii. Organizational goals and six sigma projects

b)Lean principles in the organizationi. Lean concepts and tools

ii. Value-added and non-value-added activities

iii. Theory of constraints

c) Design for Six Sigma (DFSS) in the organizationi. Quality function deployment (QFD)

ii. Design and process failure mode and effects analysis (DFMEA &

PFMEA)

iii. Road maps for DFSS

I. Overview: Six Sigma and the Organization


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II Six Sigma Define (25 Questions)

A. Process Management for Projectsi. Process elements

ii. Owners and stakeholders

iii. Identify customers

iv. Collect customer data

v. Analyze customer datavi. Translate customer requirements

B. Project management basicsi. Project charter and problem statement

ii. Project scope

iii. Project metricsiv. Project planning tools

v. Project documentation

vi. Project risk analysis

vii.Project closure



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II Six Sigma Define (25 Questions)

C. Management and planning tools

D. Business results for projects

i. Process performance

ii. Failure mode and effects analysis (FMEA)

E. Team dynamics and performance

i. Team stages and dynamics

ii. Six sigma and other team roles and responsibilities

iii. Team tools

iv. Communication



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III. Six Sigma Measure (30 Questions)A. Process analysis and documentation

i. Process modeling

ii. Process inputs and outputs

B. Probability and statistics

i. Drawing valid statistical conclusions

ii. Central limit theorem and sampling distribution of the mean

iii. Basic probability concepts

C. Collecting and summarizing data

i. Types of data and measurement scales

ii. Data collection methods

iii. Techniques for assuring data accuracy and integrity

iv. Descriptive statistics

v. Graphical methods

III. Six Sigma - Measure


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III. Six Sigma Measure (30 Questions)

D. Probability distributions

E. Measurement system analysis

F. Process capability and performance

i. Process capability studies

ii. Process performance vs. specification

iii. Process capability indices

iv. Process performance indicesv. Short-term vs. long-term capability

vi. Process capability for attributes data

III. Six Sigma - Measure


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IV. Six Sigma Analyze (15 Questions)

A. Exploratory data analysis

i. Multi-vari studies

ii. Simple linear correlation and regression

B. Hypothesis testing

i. Basics

ii. Tests for means, variances, and proportions

iii. Paired-comparison tests

iv. Single-factor analysis of variance (ANOVA)

v. Chi square

IV. Six Sigma -Analyze


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V. Six Sigma Improve & Control (15 Questions)

A. Design of experiments (DOE)

i. Basic terms

ii. Main effects

B. Statistical process control (SPC)i. Objectives and benefits

ii. Rational sub grouping

iii. Selection and application of control charts

iv. Analysis of control charts

C. Implement and validate solutions

D. Control plan

V. Six Sigma Improve & Control


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ASQ BOK Section 1:

Overview Six Sigma and the Organization


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Overview - Six Sigma and the Organization

1. Six Sigma and organizational goals

2. Design for Six Sigma (DFSS) in the organization

3. Lean principles in the organization


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ManagementProcess Management

Six Sigma Methodology


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Step 5:

CONTROL

Step 2:

MEASURE

Step 1:

DEFINE

Step 4:

IMPROVE

Step 3:

ANALYZE

D-M-A-I-C-Approach for Sustainable Improvements


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Control

Improve

Analyse

Measure

Define

Define the problem

Define the customer(s) and the requirements

Define the current capability Define the key processes that will have the greatest impact on customer

Identify the statistical measures to monitor the key process

Set up the data collection plan

Measure the process

Determine the analysis tools and methods to be used

Summarize the data measured

Run the analysis and determine the root causes, effects, etc.

Improve = Innovate and Implement

Focus on developing process/technology to improve the root cause

Test the method on sample process and validate the improvement

Standardize and document the process and implement the plan

Monitor the process and feedback the results back to the

process for continuous improvement

DMAIC Methodology


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Define - Determine Project Objectives,

Scope, Resources, Constraints, Etc.

Measure - Determine CTQs,

Obtain Data To Quantify

Process Performance

Improve - Intervene In The Process

To Improve Performance

Control - Implement A Control System

To Maintain Performance Over Time

DMAIC DMADV

Define - Similar

Measure - Determine CTQs

Analyze - Analyze Data To Identify

Root Causes Of Defects

Analyze - Develop Design Concepts,

And High-Level Design

Design - Develop Detailed Design,

Implementation and Integration

Verify - Check Completed Design,

Transition to Customer

DMAIC And DMADV Phase By Phase


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Lean is all about waste elimination

A principle driven, tool based philosophy that

focuses on eliminating waste so that all

activities/steps add value

from the customers perspective.

Lean Thinking

What is Lean Thinking ?


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1. Specify the value

2. Map the value stream

3. Establish flow

4. Implement pull

5. Work to perfection

Lean Principles


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[learn six sigma green belt for beginners in a nutshell

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