Day 1: Introduction & DEFINE Phase
Topics:
Introduction to Lean, Six Sigma & DMAIC
Roles: Green Belt vs. Black Belt
Voice of the Customer (VOC) and CTQs
Project charters and problem statements
SIPOC diagram (Suppliers, Inputs, Process, Outputs, Customers)
High-level process mapping
Topics:
Types of data (continuous vs. discrete)
Operational definitions
Measurement systems analysis (MSA)
Process mapping: Swimlane diagrams
Introduction to basic statistics
Baseline performance: Process capability (Cp, Cpk)
Topics:
Root cause analysis (5 Whys, Fishbone/Ishikawa)
Hypothesis testing basics (p-value, significance)
Correlation vs. causation
Graphical analysis (scatterplots, run charts)
Failure Mode and Effects Analysis (FMEA)
Topics:
Brainstorming and solution selection
Prioritization matrix
Pilot testing and simulation
Lean tools: 5S, Kaizen, Kanban, Poka-Yoke
Design of Experiments (DoE) – Intro
Topics:
Control plans and process monitoring
Statistical Process Control (SPC)
Control charts (X-bar, R, p, np)
Visual management and standard work
