Lean Six Sigma Yellow & Orange Belt Exercise Book / Druk 2

1 WORLD CLASS

1.1 CONTINUOUS IMPROVEMENT

1.1.1 History of Lean and Six Sigma

1.1.2 Lean principles

1.1.3 House of Quality

1.1.4 Eight types of Waste

1.1.5 CIMM–framework

1.2 CUSTOMER VALUE (VOC & CTQ)

1.2.1 CTQ – Nursing home

1.2.2 CTQ – Implementation organization

1.2.3 CTQ – Ball bearing on shaft

1.2.4 CTQ–Flowdown – Baking pancakes

1.2.5 CTQ–Flowdown – Hotel room

2 POLICY DEVELOPMENT AND DEPLOYMENT

2.1 POLICY DEVELOPMENT

2.1.1 Mission, vision and core values

2.1.2 Competitive strategies

2.1.3 Cost of Poor Quality

2.2 POLICY DEPLOYMENT

2.2.1 Change management

3 PROJECT MANAGEMENT

3.1 MANAGING A PROJECT

3.1.1 Project prioritization (OB)

3.1.2 Project charter

3.2 PROCESS IMPROVEMENT ROADMAPS

3.2.1 PDCA–roadmap

3.2.2 DMAIC–roadmap

4 CIMM LEVEL I – CREATING A SOLID FOUNDATION

4.1 PROFESSIONAL WORK ENVIRONMENT

4.1.1 5S – At the office

4.1.2 5S – On a computer

4.1.3 5S – Activities

4.1.4 5S – Gemba walk

4.2 STANDARDIZED WORK

4.2.1 Standard Operating Procedure – Paper plane folding

4.2.2 One point lesson

4.3 QUALITY MANAGEMENT

4.3.1 Effective process control methods

5 CIMM LEVEL II – CREATING A CONTINUOUS IMPROVEMENT CULTURE

5.1 VISUAL MANAGEMENT

5.1.1 Visualization in the workplace

5.2 PERFORMANCE MANAGEMENT

5.2.1 Ohno Circle

5.2.2 Root cause analysis

5.3 BASIC QUALITY TOOLS

5.3.1 Affinity diagram – Students

5.3.2 5–Why technique – Problem solving

5.3.3 Ishikawa – Pizza complaints

5.3.4 Cause & Effect matrix – Baking pancakes

EXCEL

5.3.5 Scatter plot – Electronic system

5.3.6 Pareto chart – Customer satisfaction

5.3.7 Bar chart – Corona

5.3.8 Bar chart – Top 2000

5.3.9 Bar chart – CPU2000

5.3.10 Pie chart – Flashlight production

5.3.11 Time series plot – COVID–cases

5.3.12 Time series plot – Meatballs

5.3.13 Histogram – Meatballs

5.3.14 Histogram - Welfare

5.3.15 Boxplot – Coffee pods (OB)

6 CIMM LEVEL III – CREATING STABLE & EFFICIENT PROCESSES

6.1 PROCESS MAPPING

6.1.1 SIPOC – Baking Pancakes

6.1.2 Flowchart – Flashlight production

6.2 PERFORMANCE METRICS

6.2.1 Takt time – Flashlight production

6.2.2 Takt time – Fines

6.2.3 Lead time – Letters

6.2.4 First Time Right (FTR) and Rolled Throughput Yield (RTY)

6.3 VALUE STREAM ANALYSIS

6.3.1 Three M’s and eight wastes

6.3.2 Waste identification – Logistical process

6.3.3 Process FMEA – Baking pancakes (OB)

6.3.4 Poka Yoke – Practical examples

7 CIMM LEVEL IV – CREATING CAPABLE PROCESSES

7.1 STATISTICS

7.1.1 Scale types

7.1.2 Mean and median

7.1.3 Variance, standard deviation and range (OB)

7.1.4 Probability theory – Tossing dice (OB)

7.1.5 Probability theory – Vase with marbles (OB)

7.1.6 Population versus sample (OB)

7.1.7 Measurement procedures and systems (OB)