An introduction to the Six Sigma methodology and DMAIC cycle for process improvement with a focus on the Define and Measure phases, including basic statistics for understanding sampling plans and calculating process capability.

About this course

Understand the background and meaning of Six Sigma and the five steps of the DMAIC process improvement flow: Define, Measure, Analyse, Improve and Control. Discuss what "Quality" means and how to identify the Voice of the Customer.

You will learn how to set an improvement project goal, calculate process yield, and identify Critical to Quality parameters.

You will learn how to map a process and to use the necessary statistical techniques to establish the baseline performance of a process and to calculate the process capability.

To complement the lectures, we provide interactive exercises, which allow learners to see the statistics "in action." Learners then master statistical concepts by completing practice problems. These are then reinforced using interactive case-studies, which illustrate the application of the statistics in quality improvement situations.

Upon successful completion of this program, learners will earn the TUM Lean and Six Sigma Yellow Belt certification, confirming mastery of Lean Six Sigma fundamentals to a Yellow Belt level. The material is based on the American Society of Quality (www.asq.org) Body of Knowledge up to a Green Belt Level. The Professional Certificate is designed as preparation for a Lean Six Sigma Green Belt exam.

What you'll learn

  • To understand the background and meaning of the Six Sigma methodology and the role of the DMAIC process improvement cycle.
  • To identify the Voice of the Customer and translate into Critical to Quality parameters.
  • To understand the concept of random variables, probability mass functions, and probability density functions.
  • To calculate probabilities using the Normal distribution.
  • To understand how the Central Limit Theorem applies to sample and how to set up sampling plans.
  • To understand the importance of a Measurement System Analysis in a Six Sigma project.
  • To calculate Process Yield and Process Capability.
  • To perform a risk assessment using a Failure Modes and Effects Analysis.
  • How to apply the Define and Measure phases of the DMAIC cycle in your work or research, to identify problems and quantitatively assess the impact of process changes using statistical analysis.

Course Syllabus

Week 1: Six Sigma Introduction

Introduction to the Six Sigma Methodology and the DMAIC process improvement cycle. Understand the contributors to the cost of quality. Discuss the difference between defects and defectives in a process and how to calculate process yield, including a comparison of processes of different complexity using the metric DPMO.

Week 2: Define - Defining the Problem

Discuss how to understand customer expectations, using the Kano Model to categorize quality characteristics. Start the first and difficult task of a Six Sigma project, Defining the Problem, and review the key content in a Project Charter.

Week 3: Measure - Statistics Review

Review of random variables and probability distributions used commonly in quality engineerings, such as Binomial, Poisson, and Exponential. Cover descriptive statistics, emphasizing the importance of clearly communicating the results of our project.

Week 4: Measure - Normal Distribution

Learn the characteristics of the Normal Distribution and how to use the Standard Normal to calculate probabilities related to normally distributed variables. Cover the Central Limit Theorem, and how it relates to sampling theory.

Week 5: MEASURE - Process Mapping

Introduce Process Mapping, including SIPOC and Value Stream Mapping. We identify the Critical-to-Quality characteristic for a Six Sigma project

Week 6: MEASURE - Measurement System Analysis

Learn the basics of Measurement Theory and Sampling Plans, including

Precision, Accuracy, Linearity, Bias, Stability, Gage Repeatability & Reproducibility

Week 7: MEASURE - Process Capability

Introduction to Process Capability and the metrics CP/CPK for establishing our baseline process performance.

Week 8: Quality Topics and Course Summary

Cover the basics of Tolerance Design and the risk assessment tool Failure Mode and Effects Analysis (FMEA).

Review the complete Six Sigma Roadmap before summarizing and closing the course.

Prerequisites

This course reviews basic statistics used in Six Sigma and quality management, applying them to quality problems and methods. Therefore, basic math skills are necessary.

Further Information

  • Length: 8 Weeks
  • Effort: 3–4 hours per week
  • Price: FREE; Add a Verified Certificate for $99 USD
  • Institution: TUMx
  • Subject: Business & Management
  • Level: Introductory
  • Language: English
  • Video Transcript: English
Program taught in:
  • English
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Last updated September 30, 2019
This course is Online
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