QUltima Lean Six Sigma Yellow Belt Course Contents

Practical Approach to Problem Solving

Key “take away”

  • Concepts of Basic Statistics, data analysis and Minitab
  • Introduction to Six Sigma and Lean
  • Key Steps in Problem Solving
  • Comprehensive inputs on all the 7QC Tools with introductory inputs on Six Sigma Tools
  • Lean Six Sigma Tools used in Define, Measure, Analyze, Improve and Control phases
  • Expectation from team members (Yellow Belts) during each phase & Mitigation of team challenges

Pre-read Material (To be sent in advance)

  • History of Quality and Need of Six Sigma
  • What is Six Sigma – Various approaches merging into concept
  • Cost of Quality
  • Futility of Inspection
  • Successful and not so successful stories of Six Sigma.
  • Who ultimately gains by Six Sigma initiative?
  • Problem Solving Techniques
  • Developing an eye for Improvement Opportunities (Problems)
  • Various methodologies of Six Sigma (DFSS, DMAIC, LEAN)
  • Understanding steps in Six Sigma Methodology and what to expect as QSSYB, QSSGB and QSSBB courses.
  • Understanding Team Roles and challenges as member

Day Wise Agenda

Day 1

  • Capacity Map – Understanding Equivalent Manufacturing Units, bottleneck and how to identify projects
  • Basic Statistics – 5 steps with the concept and application
  • Types of Data – Discrete (Nominal, Ordinal) and Continuous (Interval & Ratio)
  • Location / Central tendency of Data (Mean, Median, Mode)
  • Spread of Data – Range, Variance, Standard Deviation & COV
  • Shape of Data and Predictions – Part 1 – Histogram, Distributions, Normal Distribution and reason of non-normality (perspective of special causes)
  • Review of Pre-read Material (Q & A Method)

Day 2

  • Shape of Data and Predictions – Part 2 – Probability calculations for defect estimations, inventory control, cycle time estimates and negotiations.
  • Introduction to Minitab – a statistical software and parallel calculations in excel
  • Data Collection Methods
  • Define Phase –Business Metric; scoping down tools viz. basic concept of VSM, macro map, tree diagram; Pareto chart; primary metric, financial metric, negative consequence metric; team constitution, problem & objective statements
  • Measure Phase – Part 1 – Accuracy, Precision, Capability Measures, Short term & long term
  • Review of Pre-read Material (Q & A Method)

Day 3

  • Measure Phase – Part 2 – Process Flow Diagram, hidden factories, VA/NVA, KPIV/KPOV identification, Fish Bone Diagram and C&E Matrix
  • Analyze Phase – FMEA and Graphical Analysis. Basic Concept of SMED.
  • Improve Phase – Types of Experimentation, difference between DOE and OFAT, Basic of Kanban.
  • Control Phase – Control Methods and their hierarchy, control plan, Statistical Process Control – Which control chart to use where, making of Xbar-chart, interpretation of control charts
  • Review of Pre-read Material (Q & A Method)

Prior Knowledge Requirement

Basic knowledge of excel for mathematical operations and exposure to 7QC Tools.