Implement Lean Six Sigma

Lean Six Sigma is an integrated set of methodologies that combines both traditional Lean and Six Sigma concepts to provide the necessary tools to address all aspects of quality, cost, and delivery. Lean Six Sigma is a powerful approach that allows organizations to achieve targeted value more quickly at the lowest possible cost, while aligning processes with customers.

At the end of the training programme, the learners will be able to apply strategies, methods and tools used
for developing and implementing lean six sigma project plans, such as:
1. Map and evaluate business process using Value Stream Mapping tool
2. Defines and establish the value flow
3. Identify and analyse non-value added process using VSM tool
4. Design, measure, evaluate and implement improvements

Introduction to Lean
- Identify a situation where lean can be a benefit
- Explain the benefits of going lean
- List and define five principles of lean
- List the eight types of waste and how to correct them
- Differentiate value-added work from waste
- Quantitatively assess your organisation’s lean readiness
- Determine product families that share common processes

Lean Culture
- Explain the importance of respect for people, change management, and continuous improvement in the lean philosophy
- Explain the forming, storming, norming, performing, and reforming stages of team development
- Conduct a kaizen event and fill in a kaizen report
- Explain the concept of jidoka, including line stop, operator flexibility, and poka-yoke
- List five criteria for choosing a lean pilot product family

Value Stream Mapping
- Explain how value stream mapping fuels continuous improvement
- Create a current-state map using standard icons
- Accurately calculate takt time to determine if a process can meet customer demand
- Incorporate value stream concepts to create a future-state map

Stability & Process Improvement
- Determine methods to achieve market demand stability
- Utilise three methods to level a value stream
- Give three methods to improve process stability
- Give three standard work components and the benefits of standard work
- Evaluate and reduce setup time using the 5S tool
- Explain how the six sigma methodologies apply to process stability

Just-in-Time
- Explain Just-in-Time
- Compare and contrast one-piece and batch flows
- Explain production cell varieties
- Explain kanban card line operations
- Level the schedule using takt time, one-piece flow, and heijunka

Measuring
- Compare lean to traditional accounting and measuring
- Create a profit and loss (P&L) statement for a value stream and compare to a standard cost P&L
- Create a performance alignment chart
- Explain seven lean measurements
- Explain how negative financial results may result from lean transformations
- Calculate lead time through production

Sustaining
- Describe three reasons for implementing DFMA
- Explain how to determine technical design priorities using a house of quality matrix
- Utilise cause and effect to determine required design controls using an FMEA
- List the seven quality control tools
- Utilise Plan-Do-Check-Act and six sigma DMAIC
- Create an action plan to implement and sustain lean principles in their organisation

This is an industry oriented programme and candidates should preferable possess the following:
• Diploma in any discipline and/or
• A minimum of 3 years working experience
• Language proficiency is English, at GCE N' Level

An applicant must be at least 18 years of age on admission to the programme.

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