Lean six sigma training

#181

Back in college third year, KPMG offered a 2-day workshop on Lean six-sigma training. Here are some of the things I learned about:

Day 1:

1. Systematic, data-driven approach - problem-solving
2. Convert business problem and solution to statistical problem and solution (infer from business)
3. Problem - chronic/long-lasting: addressing it will be impactful
4. D: Define or identify problem statement
5. M: Measure or identify factors influencing barriers to achieving the goal
1. Factors: people, technology, environment competitors, past experience
6. Assumption - all people using the process produce the same results
7. A: Analyze - regression analysis
8. Bell curve - depicts average 
9. Y - lagging indicator - CTQ - critical to quality (people: skill, process: variation, tech: compliance)
10. X - leading indicator
11. Bill Smith - production engineer - came up with MLAC
1. Michael Harry + Bill Smith - evaluation of six sigma
12. Six sigma: 3.4 maximum defects per million opportunities
13. Requirements -> design -> developments -> validation (CTQ)
14. Paradigm shift:
1. From quality being the effect to being the cause
2. Presence of process mandatory to maintain consistency
3. As-is -> to be: comply with ISO
15. Role of management: change process in lieu of people
16. Six sigma approaches (2)
1. DMAIC - existing process
1. D: customer expectations
1. Select performance characteristics critical in meeting customer requirements
2. M: defects frequency
1. Create + validate measurement system
3. A: why, when, where
1. Identify sources of variation from performance objectives
4. I: fix
1. Discover process relationships + establish new procedures
5. C: stay fixed
1. Monitor implemented improvements to maintain gains
2. DMADV - for new process
17. Affinity diagram
18. Kano model
19. Project scoping tool - in/out frame
20. GRPI checklist - goals, roles, processes, interpersonal relationships
21. VOC - voice of customer - customer comment, issue, critical requirement
22. SIPOC - supplier, input, process, output, customer
23. Levels of process mapping

Day 2:

1. Deliverables
2. Fishbone diagram
3. 7Ms - machine, method, measurement, man, mother nature, material, money
4. 5Ps - promotion, price, people, processing, packaging
5. Cost-benefit analysis
6. Control impact matrix
7. Data collection plan, sampling
8. MSA - measurement system analysis
9. Fleiss’ Kappa
10. Kendall’s coefficient of concordance 
11. Minitab, box plot, run chart, rolled throughput yield, pareto chart, work-value analysis, cycle-time analysis, hypothesis testing - t test, anova, chi-square, TRIZ - theory of inventive problem-solving
12. Process management system
1. Documentation and standardization
2. Monitoring
3. Response plan
13. Control variables
1. Mistake 1 - tampering
2. Mistake 2 - under-reacting
14. Effectiveness of implemented solution 
1. KPI - key-performance indicator
2. KRA - key responsibility area
15. Retrospection - project closure