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PROCESS SOLUTIONS INTERNATIONAL uses only the best materials available.


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 (SPC-XL, DOE PRO-XL, 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.


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.


(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.


Building a Six Sigma Culture
Roles and responsibilities
Six Sigma Project master strategy
Six Sigma Implementation strategy
What is Six Sigma
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
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
Run charts
Scatter diagrams
Numerical measures
Cp, Cpk
Dpu, dpmo
Sigma level, sigma capability
Practice with SPC XL
Measurement System Analysis
Importance of understanding the measurement process
X-bar/R and ANOVA methods for continuous data
Binary or inspection data
Precision-to-Tolerance ratio (P/TOL)
Precision-to-Total ratio (P/TOT)
Graphical analysis
Statapult Exercise
Practice with SPC XL
Building a Knowledge Notebook

Six Sigma Project Work


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 (Z-test)
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
X-bar/R, X-bar/s, IMR, p and c charts
Practice with SPC XL
Regression Analysis
Philosophy and Terminology
Interpretation of output
Practice with SPC XL
Six Sigma Project Reports (status updates) given by participants


Foundations and Overview of DOE
Strategies (screening, modeling)
Y-hat and s-hat models
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 two-level Designs

Summary of three-level Designs

Analysis and Case Study Examples Variance Reduction and Robust Design
Taguchi’s inner/outer array
Variance reduction using s-hat models
Six Sigma Project Reports (status updates) given by participants


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 Wrap-up

Six Sigma Project Reports (status updates) given by participants


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 in-class 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:
S-hat Modeling
Interaction and Contour Plots
Process Capability Measures (dpu, yield, dpm, sigma capability, Cp, Cpk)

Probability Distributions, to include:
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:
X-Bar – R Charts
X-Bar – S Charts
Individual Charts
Run Charts
Design of Experiments (DOE), to include:
Both 2-level and 3-level designs
Both screening and modeling designs
Regression analysis using DOE KISS and Multisim
Graphical analysis using response surfaces, contour plots, and interaction plots
Y-hat and S-hat models
Multiple response optimization using DOE PRO
Rules of Thumb for design selection and sample size
Measurement System Analysis (MSA), to include:
Both the X-Bar – R and ANOVA methods for continuous data
Binary or inspection data
Knowledge of Precision-to-Tolerance (P/TOL), Precision-to-Total (P/TOT) ratios, resolution, and graphical analysis


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 ease-of-use.


SOFTWARE by: Digital Computations and Air Academy Associates

SPC-XL - 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 Pro-XL - 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.


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 "what-if" simulations to achieve the smoothest operating and optimized processes without costly trial-and-error 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!!


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 top-rated 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.

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