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Through our approach to teaching Six Sigma, we have helped numerous individuals and groups to master the skills necessary to efficiently monitor, improve, characterize, and optimize their processes. We incorporate hands-on demonstrations with training aids such as the Statapult to enhance understanding and to make learning fun. Our goal is to do more than teach SPC and DOE...it is to insure that our course participants enjoy themselves and are able to put the concepts into action!

The following materials are provided to each workshop attendee:
Participant Guide

Week 1:
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 Taguchiís 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

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 (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

Week 3:
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
Taguchiís inner/outer array
Variance reduction using s-hat 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 Wrap-up

Six Sigma Project Reports (status updates) given by participants

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