
MATERIALS
and SOFTWARE

PROCESS SOLUTIONS INTERNATIONAL uses only the best materials
available.
SIX SIGMA MATERIALS (DMAIC  DFSS)
PSI has partnered with Air Academy Press for our Six Sigma
DMAIC materials, including their fully integrated textbooks (Knowledge Based Management, Basic Statistics and Understanding
Industrial Designed Experiments), Student Particpant's Guides, and software (SPCXL, DOE PROXL, DFSS MASTER, MultiSim, and
Knowledge Notebook), following the "Keep It Simple Statistically" (KISS) philosophy pioneered by Air Academy Associates.
We use the materials as our foundation for your learning, and will customize the course to meet your specific requirements.
A
NOTE ON THE NEED FOR CANDIDATE MENTORING and COACHING
Candidate Mentoring and Coaching by experienced Masters is critical
to initial learning and project success. This simple fact has been proven time and again, yet many companies attempt to "save
money" by eliminating candidate Mentoring and Coaching from their training agenda.
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GREEN
BELT / BLACK BELT COURSE OUTLINE (Green Belt Training consists of Weeks 1 and 2 only)
Training participants must
have defined their DMAIC projects prior to the first week of training. Training weeks are separated by three to four week
periods for the candidates to apply their knowledge to the projects. Projects will be reviewed in class during weeks 2 thru
4. Mentoring and coaching on an individual basis will occur the second week after each training session.
WEEK 1:
Building
a Six Sigma Culture Infrastructure Roles and responsibilities Six Sigma Project master strategy Six Sigma
Implementation strategy What is Six Sigma Terminology IPO (Input Process Output) diagrams Graphical meaning
of average and standard deviation Introduction to measures of quality (Cp, Cpk, sigma level, first pass yield, defects)
Cost of Poor Quality Knowledge Based Management Strategy (role of questions, critical thinking) Prioritize, Characterize,
Optimize, Realize (PCOR) strategy Variance reduction using PF/CE/CNX/SOP Statapult and Card Drop Exercise The
What and Why of Total Quality Total Quality Principles Philosophy of KBM Relationship to Six Sigma Six Sigma
Change Model Change Management The Role of Statistics in Process Improvement Applications of Statistics Philosophy
of Quality and Taguchi’s Loss Function Terminology Metrics (developing and validating) Failure Mode and Effect
Analysis (FMEA)/Mistake proofing IPO Matrix Practice with SPC XL Making Sense out of Data using Graphical and
Measurement Tools Graphical analysis Pareto diagrams Histograms Run charts Scatter diagrams Numerical
measures Cp, Cpk Dpu, dpmo Sigma level, sigma capability Correlation Practice with SPC XL Measurement
System Analysis Importance of understanding the measurement process Xbar/R and ANOVA methods for continuous data
Binary or inspection data Metrics PrecisiontoTolerance ratio (P/TOL) PrecisiontoTotal ratio (P/TOT) Resolution
Graphical analysis Statapult Exercise Practice with SPC XL Building a Knowledge Notebook
Six Sigma
Project Work
WEEK 2:
Probability Distributions Normal, binomial, and Poisson distributions Real
world applications and use for problem solving Practice with SPC XL Sampling Distribution and Confidence Intervals
Why do we sample? Application of the Central Limit Theorem Meaning of Confidence Confidence intervals and
Sample Size Calculations Continuous data (average) Binary data (proportion) Practice with SPC XL Hypothesis
Testing with Rules of Thumb Understanding the null and alternative hypotheses Type I and type II errors Detecting
significant shifts in the average (t test) Detecting significant shifts in the standard deviation (F test) Detecting
significant shifts in a proportion (Ztest) Chi square Test for Independence (categorical data) Practical rules of
thumb for significance Statapult Exercise Practice with SPC XL Process Control and Process Capability Philosophy,
construction and interpretation of control charts Control chart selection Xbar/R, Xbar/s, IMR, p and c charts Exercises
Practice with SPC XL Regression Analysis Philosophy and Terminology Interpretation of output Exercises
Practice with SPC XL Six Sigma Project Reports (status updates) given by participants
WEEK 3:
Foundations
and Overview of DOE Terminology Strategies (screening, modeling) Yhat and shat models Exercise Practice
with DOE KISS Introduction to Design and Analysis 12 step template for DOE graphical analysis of data using response
surfaces, contour plots, interaction plots and marginal means plots statistical analysis of data examples and exercises
practice with DOE KISS Rules of Thumb Selecting designs Determining sample size Testing for significance
Interpreting computer output Regression Modeling in DOE
Summary of twolevel Designs
Summary of threelevel
Designs
Analysis and Case Study Examples Variance Reduction and Robust Design Taguchi’s inner/outer array Variance
reduction using shat models Six Sigma Project Reports (status updates) given by participants WEEK
4:
Special Topics in DOE tailored to participant project needs
Workshop activities using Multisim process
simulation software
Introduction to Multiple Response Optimization
Introduction to DOE Pro software
Course
Wrapup
Six Sigma Project Reports (status updates) given by participants

DESIGN FOR SIX SIGMA COURSE OUTLINE Introduction
to DFSS Keeping Score Voice of the Customer Systems Engineering and Requirements Flowdown Transfer Function
Design for Robust Performance Tolerance Allocation Design for Manufacturability Product Capability Prediction
Test and Validate Design for Six Sigma: Prerequisites Participants are expected to have management
sponsorship. Participants should bring a laptop computer to class with Excel 97 (or above) so that they can install the supplied
software and practice using it during many inclass exercises. A basic working knowledge of Windows and Excel is crucial.
In addition, participants should be familiar with SPC XL, DOE KISS, DOE PRO, and Multisim. Subjects that the
participants need to be familiar with:
Knowledge Based Management Strategy (Questions Managers Need to Ask and Answer)
Variance Reduction Methods, to include: PF/CE/CNX/SOP Shat Modeling Interaction and Contour Plots Process
Capability Measures (dpu, yield, dpm, sigma capability, Cp, Cpk)
Probability Distributions, to include: Normal
Exponential Uniform Binomial Poisson Hypothesis Testing, to include: Understanding the null and alternative
hypotheses Type I and Type II errors Risks of false detection and missed detection Statistical Process Control,
to include: XBar – R Charts XBar – S Charts Individual Charts Run Charts Design of Experiments (DOE),
to include: Both 2level and 3level designs Both screening and modeling designs Regression analysis using DOE
KISS and Multisim Graphical analysis using response surfaces, contour plots, and interaction plots Yhat and Shat
models Multiple response optimization using DOE PRO Rules of Thumb for design selection and sample size Measurement
System Analysis (MSA), to include: Both the XBar – R and ANOVA methods for continuous data Binary or inspection data
Knowledge of PrecisiontoTolerance (P/TOL), PrecisiontoTotal (P/TOT) ratios, resolution, and graphical analysis

SOFTWARE
Extremely powerful, easy
to work with and understand software that doesn't require a statistician to use, and doesn't require a huge investment to
purchase. No more long hours trying to learn complicated software  so intuitive that you can use it within minutes, right
out of the box!
Call or email us to find out how you can "test drive" this software  See for yourself its power and
easeofuse.
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SOFTWARE by: Digital Computations
and Air Academy Associates
SPCXL  A complete SPC solution integrated into Microsoft Excel. Create Control Charts,
Histograms, Pareto Charts, Summary Statistics, Process Capability (Ppk/Cpk, Pp/Cp) Scatter Plots, Measurement System Analysis
/ Gage R&R, FMEA and much more.
DOE ProXL  The Ultimate in Design of Experiments packages. Two and three level,
multiple response capability with advanced analysis and optimization features enables you to take control of your experiments,
all from within Microsoft Excel.
DFSS Master  Tools for the Design for Six Sigma practitioner. Features include Monte
Carlo Simulation, Tolerance Allocation, Parameter Design, Design Scorecard, and more.
MultiSim  A simulation package
for teaching DOE. Users can create and analyze designs, and optimize processes. An excellent package for those who need
to practice Design of Experiments.
Knowledge Notebook  All the forms and templates necessary to keep track of your
DMAIC / DMADV / IDOV projects. Provides standard format and common language for your project data and information.
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SOFTWARE
by: ProcessModel
ProcessModel version 4.2.7  This powerful software performs Process Flow and Value Stream Analysis
simulations, allowing you to graphically create and improve your business processes on your computer. Simulate WIP, queue,
input distributions  your entire process, as it is. Then create the future state process and run "whatif" simulations to
achieve the smoothest operating and optimized processes without costly trialanderror experimentation and guesswork. Not
sure of the input distribution? No problem  ProcessModel will determine the distribution of your data so there is no guesswork
here, either  this is s really nice feature!!

COPYRIGHTED TRAINING MATERIALS
Our "Project Management
for Process Improvement Projects" three day seminars and materials have been presented through the Extended Studies and Professional
Development Departments of many toprated colleges and universities, including: Pepperdine Graziadio School of Business and
Management, University of Chicago, UC Berkeley, Rutgers, Towson, George Mason, Michigan State Eli Broad School of Business,
San Diego State, and Colorado State.




