Lean Six Sigma training

1. About Us
About LSMI – www.leansigma.asia About Dr.Jagadish Barik
(Lean Sigma Management Institute) Dr Jagadish Barik has nearly twenty one years of
The Dr. Jagadish Barik’s Lean Sigma experience in manufacturing & Service Industries
Management Institute (LSMI) is focussed on in deployment of Lean, Six Sigma, Business
high quality, customer responsive education Excellence models ( RBNQA,CII-EXIM, Deming)
,consultancy, research and advisory TQM ,TPM, 5S,BSC, BPMS, SPC, Kaizen,
services to corporations & goverments. Visual Management, Quality Circle, Idea
Education solutions involve training and Management, Change Management and other
certification programs and related Quality initiatives . Through research of all best
consultancy services supported by research practices being followed at Japan and U.S.A ,he Training & Certification Programs
and concentrating on areas of specific has developed a simple, Jargon free ( Joint Certification by LSMI & NCQM)
corporate and government development and and integrated 6-level total organisational • Six Sigma Green Belt (ASQ/ Dr.Mikel Harry’s
About Us
enquiry. Primary purpose of LSMI is to excellence model for organisations to
Six Sigma Management Institute) – 4 days
provide training and consultancy to become worldclass , suitable for Indian
industries and culture . He has deployed Lean • Six Sigma Black Belt (ASQ/SSMI) – 16 days
business organisations for improving • Six Sigma Black Belt- DFSS – 5 days
quality, productivity and customer Six Sigma initiatives in various organisations
across the globe such as SKF, Reliance,Hankel, • Six Sigma Master Black Belt – 20 days
satisfaction while reducing cycletime and
cost . Xchanging Technology etc. • Lean Expert – 4 days
• Statistical Process Control- 3 days
About National Centre of Quality He is a Certified Six Sigma Black Belt from ASQ, • Business Process Transformation (BPT)- 1 day
Management ( NCQM) : www.ncqm.com QCI & QIMPRO and Certified Master Black Belt • Kaizen basics – 1 day
NCQM was established in 1985 by a group of from ISI-Bangalore. He is trained and • Kaizen Event- 5 days
eminent industrialists and professionals as Certified on WCM/Lean by Confederation of
• Quality Circle – 2days
a not-for-profit organization devoted to Indian Industies (CII). He is trained and Certified
by AOTS, Japan on Quality Management· He
• Measurement System Analysis – 1 day
promote quality at National Level. It is a
has hands on exposure at Toyota Production • Process capability study – 1 day
premier professional institution engaged in
promoting Quality culture in Indian Sstems. He has trained more than 1000 Green • Quality Function Deployment- 1 day
economy through services like training, Belts and more than 200 Black Belts in DMAIC, • KANO Analysis – 1 day
education, seminars, publications, research DFSS and LEAN methodology. He has • Design of Experiment – 3 days
and advisory services. completed and coached more than 600 projects • Failure mode and effect analysis- 1 day
across various organisations in manufacturing • 5S Workshop – 2days
and service areas across the world. He is a • Value Stream Mapping – 1 day
certified examiner for RBNQA & CII-EXIM • Problem solving tools – 2 days
business excellence award. He is a Sr.Member
• Change Management – 1day
of ASQ, Six Sigma forum, ISQ, IAOP,
ISSP,AIMA, DMA and Centre coordinator of • Lean Six Sigma Overview – 1 day
NCQM at Delhi-NCR. • Advance Statistical Tools – 3 days
• Cost of Poor Quality (COPQ)- 1 day

2. ASQ- Green Belt - 4 Days
INTRODUCTION PROGRAM CONTENTS
The American Society for Quality (ASQ) is the world's DAY- 3 & 4 :
leading authority on quality. With more than 100,000 DAY – 1 & 2 : ANALYSE PHASE
individual and organizational members, this OVERVIEW-SIX SIGMA Analyze Opportunity –
professional association advances learning, improves Six Sigma Overview
quality and exchanges knowledge to improve What is wrong?
Green Belt - Course Overview
business results and to create better workplaces and Six Sigma and organisational goal
communities worldwide. Lean principles Exploratory data analysis
Design for Six Sigma ( DFSS) Hypothesis testing
Certification from ASQ is considered a mark of quality Chi square test
excellence in many industries. It helps you advance DEFINE PHASE ANOVA
your career and boosts your organization’s bottom line
Program Details
Define Opportunity – Regression Analysis
through your mastery of quality skills. Becoming
certified as a Six Sigma Green Belt confirms your What is important?
IMPROVE PHASE
commitment to quality and will have the positive
impact on your organization.
Improve Performance –
Process Management for projectss
PROGRAM OVERVIEW Project management basics What needs to be done?
The ASQ Six Sigma Green Belt Program gives Management and planning tools
participants the skills and knowledge they need for the Business results and projects Introduction to DOE
exceptional leadership of business improvement Team dynamics and performance Full factorial design
projects. Upon completing each segment of training, Solution implementation
participants immediately apply concepts and tools MEASURE PHASE
taught in training to their real-time improvement Measure Performance – CONTROL PHASE
projects. How are we doing? Control Performance –
Six sigma is a highly disciplined approach used to
reduce the process variations to the extent that the How do we guarantee
level of defects are drastically reduced to less than 3.4 Process analysis and documentation performance ?
per million opportunities (DPMO). Six sigma is a Probability and statistics
po wer f ul appr o ach t o achi e ve breakthrough Collecting and summarising data
Probability distribution Statistical Process Control (SPC)
improvements in manufacturing, engineering and Integrate processes.
Service processes. Over the past 20 years, use of Measurement system analysis
Process capability and performance Control Strategy
Six Sigma, the popular business improvement Close project
methodology, has saved Fortune 500 companies
a n e s t i m a t e d $ 4 2 7 b i l l i o n

3. ASQ- Black Belt - 16 Days
INTRODUCTION
The American Society for Quality (ASQ) is the world's PROGRAM CONTENTS Week- 2&3 : Eight Days
leading authority on quality. With more than 100,000 MEASURE PHASE
individual and organizational members, this Week- 1&2 : Eight Days Process Characteristics
professional association advances learning, improves ENTERPRISEWIDE DEPLOYMENT Data collection
quality and exchanges knowledge to improve Measurement systems
# Enterprise
wide view
Black Belt - Course Overview
business results and to create better workplaces and Basic statistics
communities worldwide. # Leadership Probability
Process capability
Certification from ASQ is considered a mark of quality ORGANISATIONAL PROCESS ANALYZE PHASE
excellence in many industries. It helps you advance MANAGEMENT Measuring and modelling relationships
your career and boosts your organization’s bottom line
Program Details
between variables
through your mastery of quality skills. Becoming # Impact on stakeholders Hypothesis testing (Chi-sq, ANOVA)
certified as a Six Sigma Green Belt confirms your # Critical to X (CTX) requirements FMEA
commitment to quality and will have the positive # Benchmarking Additional analysis methods
impact on your organization. # Business performance measures IMPROVE PHASE
# Financial measures Design of Experiment (DOE)
PROGRAM OVERVIEW
The ASQ Six Sigma Green Belt Program gives waste elimination
TEAM MANAGEMENT Cycle time reduction
participants the skills and knowledge they need for the
exceptional leadership of business improvement Kaizen
# Team formation Theory of Constraint
projects. Upon completing each segment of training,
# Team facilitation Implementation
participants immediately apply concepts and tools
# Team dynamics Risk analysis & mitigation
taught in training to their real-time improvement
# Team management CONTROL PHASE
projects.
# Team decision making tools Statistical Process Control (SPC)
Six sigma is a highly disciplined approach used to
# Management and planning tools Other control tools (TPM,5S…)
reduce the process variations to the extent that the
# Team performance evaluation and Maintain control
level of defects are drastically reduced to less than 3.4
rewards Control plan
per million opportunities (DPMO). Six sigma is a
po wer f ul appr o ach t o achi e ve breakthrough DFSS
DEFINE PHASE Common DFSS Methodology
improvements in manufacturing, engineering and
Voice of Customer Design for X (DFX)
Service processes. Over the past 20 years, use of
Project charter Robust design and process
Six Sigma, the popular business improvement
Project tracking Special design tools
methodology, has saved Fortune 500 companies
a n e s t i m a t e d $ 4 2 7 b i l l i o n

4. Lean Expert - 4 Days
INTRODUCTION. COURSE DURATION
PROGRAM CONTENTS
Lean focuses on three things- Elimination 4 days
of Waste and Non Value Added activities, WHO SHOULD ATTEND
brings process speed and establish the flow. Managers, change agents, Lean Six Sigma Lean evolution
It evaluates the entire operation of the practitioners or others that desire an Toyota Production System
factory and restructures the manufacturing/ Lean overview
Lean Expert - Course Overview
understanding of Lean principles
service method in order to reduce wasteful COURSE INCLUDES Integration of Lean into Six
activities like waiting, transportation, Training Handouts Sigma
material hand-offs, inventory, over- Training Completion Certificate Baseline assessment
production, etc. It co-locates the processes Certified Lean Expert Certificate on Product and service family
in sequential order. As such, it reduces successful completion of training , test & Voice of the customer analysis
Program Details
variation associated with manufacturing one Lean project Supply Chain Mapping
routings, material handling, storage, lack of Project coaching Value stream Mapping
communication, batch production etc. Lean WHAT YOU WILL LEARN Product flow analysis
methodology focuses on product flow and How to apply Lean methods to improve Operators activity analysis
on the operator. How can we produce the response to customers’ requirements in Set up time reduction/ SMED
product in the least amount of time, and timelines, quality and cost needs Standardisation
how do we standardize the operator How workflow fits into the roadmap to Pull system/ KANBAN
methods and give the operator what he/she deploy Lean in an organization. Mistake proofing/Poka yoke
needs? How Lean and Six Sigma Cell design and implementation
complement each other. Cell performance measurement
How waste, value-added and non Continual improvement
value-added activities affect process Case studies and Simulations
efficiency.
How to construct a Value Stream Map
to identify areas for improvement.
How to determine Lean opportunities
vs. Six Sigma opportunities.
How to balance workload among
employees
How to standardise processes and
systems

5. Black Belt (DFSS) - 5 Days
INTRODUCTION. PROGRAM CONTENTS
COURSE DURATION
Companies that excel at designing 5 days
DEFINE PHASE DESIGN PHASE
more effective ways of accomplishing WHO SHOULD ATTEND
Build system and sub-system
Black Belt (DFSS) - Course Overview
basic business tasks are best poised Six Sigma Green Belt/ Black Belt Identify product/process
to excel in today’s competitive who has completed at least one performance models
business environment. project Project charter & CTQs Generate transfer function
COURSE INCLUDES Set quality goals Statistical analysis and variance
Design for Six Sigma’s DMADOV Training Handouts Quality function Deployment drivers Design of experiment
(Define-Measure-Analyze-Design- Training Completion Certificate (QFD)- House of Quality- 1 Axiomatic design
Optimise-Verify) methodology is a Certified Black Belt (DFSS) Kano analysis Function audit
powerful tool for improving innovation Certificate on successful Survey design Process capability flow up for all
Program Details
and design. This program helps Six completion of training & test subsystem
Sigma practitioners apply DFSS WHAT YOU WILL LEARN MEASURE PHASE
concepts so that they can foresee How to design new products CTQ flow down and transfer OPTIMISE PHASE
and eliminate defects before and using the DMADOV methodology. Function structure Optimise design
during the design process. When to use DMADOV over Six Measurement system analysis Statistical tolerancing
Sigma’s DMAIC process. Capability study Modeling and sensitivity
This five-day program is designed Practical applications of DFSS Taguchi robust design
to help participants master a variety tools. ANALYZE PHASE Error proofing
of techniques for the design process. Robust Design of Experiments QFD- House of quality- 3 & 4
Develop conceptual designs
DFSS is built around the idea that (DOE) techniques. VARIFY PHASE
Innovation and creativity
“design” is truly a cross-functional Product tolerance analysis Six thinking hats
undertaking. No longer is it the sole including the Monte Carlo Product/process design
TRIZS/ TIPS
responsibility of the “Product Simulation. varification
Design for reliability
Designer” . While the course focuses How to properly analyze Develop manufacturing &
DFSS Score card
on statistical design tools, it also reliability data. suppliers control plans
Risk assessment
emphasizes project management and How to apply the principles of Document and transition
Design FMEA
includes an in-depth discussion of Design for Manufacturing & Pugh matrix
topics such as listening to and Assembly (DFMA). QFD- House of quality- 2
understanding the customer, How to select appropriate
Converting customer requirement to maintenance strategies for
process specifications and defect free products.
des ign right at the f irst time .

6. Master Black Belt - 20 Days
INTRODUCTION. COURSE DURATION PROGRAM CONTENTS
A master black belt is very highly 20 days Spread across 4 months Week- 3 :
proficient in the six sigma tools and WHO SHOULD ATTEND Week- 1 :
DOE – Full factorial
Master Black Belt - Course Overview
can train others in the methodology. Six Sigma Black Belt who has MBB Introduction
DOE-Fractional factorial
Number of master black belts may completed at least one project MBB Program review
DOE- Aliasing
be very few in the organisation. COURSE INCLUDES Presentation skills
DOE- Blocking
Training Handouts Message maps
DOE- Centre point
Our Master Black Belt program Training Completion Certificate T-MAP
DOE- Response surface
is designed to help Black Belts Certified Master Black Belt SIPOC
design
transition into the Master Black Certificate on successful P-MAP
DOE- Mixture design
Belt role by providing them with all completion of MBB Criteria FMEA
Program Details
DOE- Axiomatic design
the tools they need to be successful WHAT YOU WILL LEARN Variation and statistics
DOE- Orthogonal array
teachers, coaches, project leaders How to manage the change Distribution and
designs
and Champions. These courses How to create infrastructure for transformation
DOE- Taguchich designs
help practitioners build a mix of both Lean Six Sigma initiatives MSE-Variable
Other optimisation techniques
hard and soft skills. How to select business critical MSE- Attribute
projects Effective team Week-4 :
How to conduct GB/BB training Change leadership MBB- Lean Manufacturing
How to guide and coach the MBB-Lean services
projects Week-2 : Creativity tools
How to integrate Lean Six Sigma Sampling & CLT Six thinking hats
with other existing best practices MBB-Capability study Lateral thinking
How to institutionalise change Parametric hypothesis TRIZ
management testing Innovation
MBB CERTIFICATION CRITERIA Non parametric hypothesis MBB- DFSS
testing MBB-Six Sigma
Complete 4 weeks of MBB Turkey test deployment workshop
training MBB-ANOVA MBB- Institutionalisation of
Co-teach one complete GB/BB MBB-Regression six sigma
program with LSMI MBB MBB- Practice sessions on
Coach and mentor 2 BB projects teaching, project coaching
Complete one MBB project

7. Statistical Process Control - 3 Days
INTRODUCTION. COURSE DURATION PROGRAM CONTENTS
Statistical methods are effective tools for 3 days
improving the process and reducing the Introduction to SPC
defects. People often try to reduce defects by WHO SHOULD ATTEND Basic statistics
tracing directly back to the cause of the defect. Managers, Process Engineers, change agents, Basic characteristics of the process
This is a straight forward approach and , at a Lean Six Sigma practitioners or others that Sampling & data collection plan
glance, it seems to be efficient. But, in most desire an understanding of SPC Pareto analysis
cases , causes the causes obtained from that Cause and effect diagram
SPC - Course Overview
approach are not true ones. Attempts bacome COURSE INCLUDES Histogram
abortive and the effort wasted Training Handouts Scatter diagram
Training Completion Certificate Process Capability study
Program Details
Minitab guide Basics of control charts
Certified SPC professional Run chart
Statistical tools lend objectivity accuracy to I-MR chart
observations. The maxims of statistical way of WHAT YOU WILL LEARN X bar- R chart
thinking are : Understanding of basic statistics X bar-S chart
How to know the current Attribute control charts
1. Give greater importance to facts than capability of the processes P- Chart
abstract concepts How to enhance process C- Chart
2. Do not express facts in terms of senses or capability NP- chart
ideas . Use figures derived from specific How to identify the problem areas U-Chart
observational results How to prioritise the problem areas Introduction to Minitab
3. Provides you adequate informations to take How to set a stretch target Methodology to deploy SPC
correct decisions How to take identify the root cause Case Studies
Basic problem solving tools
This three days training program aims to How to monitor and control the process
illustrate the application of statistical methods
to real world problems with case studies SPC PROFESSIONAL CERTIFICATION
CRITERIA
Completion of training
Test Score >70%

8. Business Process Transformation- 1 Day
INTRODUCTION. COURSE DURATION PROGRAM CONTENTS
Operations are composed of processes that 1 day
add value. Enhancing processes can contribute WHO SHOULD ATTEND Create Process Mission
to the success of organizations. Step-by-step Managers, Process Engineers, change agents, Document Process- SIPOC
approach to process analysis ensures better Lean Six Sigma practitioners or others that Document process – AS-IS
success.These steps are: desire an understanding of Business Process Value stream mapping
Transformation methodology DocumentCustomer&Process
1. Define the problem COURSE INCLUDES requirements
BPT - Course Overview
2. Gather data to describe the problem Training Handouts Identify Output & Process Measures
3. Determine possible causes Training Completion Certificate Build process management system
4. Select the root cause Certified BPT professional Establish data collection plan
Program Details
5. Develop solution strategies Process performance monitoring
6. Test and evaluate solutions WHAT YOU WILL LEARN Develop dashboards with spec limits
What is difference between activity, process & & targets
Constant change is new reality in the world of system Identify improvement opportunities
business. A systematic process analysis What is process maturity model
methodolog y helps identify and correct How processes mature over a period of time
bottlenecks and helps in eliminating any waste. How to identify L-1, L-2, L-3… Processes
Process analysis activity should be undertaken How to transform process through 10 step
on a regular basis to help in increasing the model of BPT
capacity, take full advantage of the processes, How to manage process through metrics
improve throughput and reduce cycle time management
How to identify potential improvement
projects
How to prioritise of improvement projects
How to involve employees in BPT
BPT PROFESSIONAL CERTIFICATION
CRITERIA
Completion of training
Test Score >70%

9. Kaizen Basic Training- 1 Day
Kaizen Event – 5 Days
INTRODUCTION. COURSE DURATION PROGRAM CONTENTS
Kaizen comprises Japanese words kai and zen 1 day
where kai means change and zen means good. WHO SHOULD ATTEND Kaizen Introduction
The popular meaning is continuous Managers, Process Engineers, change agents, Kaizen Infrastructure set up
improvement of all areas of a company not just Lean Six Sigma practitioners, people at shop 6- level kaizen deployment model
quality . Kaizen focuses on waste , delivering floor or others that desire an understanding of Identification of seven types of waste
value to customer and create value in process. Kaizen methodology Kaizen Issue identification workshop
Kaizen - Course Overview
COURSE INCLUDES Kaizen Improvement workshop
1 day basic training give the familiarisation to Training Handouts Kaizen review workshop
Kaizen and preparation to launch ‘Kaizen Training Completion Certificate Kaizen event planning and execution
Events’ in any organisation or process. 5 days Certified Kaizen professional Kaizen certification to teams
Program Details
‘Kaizen event’ some times called ‘Kaizen Blitz’ Kaizen integration with existing other
Provides a well planned , focused and rapid WHAT YOU WILL LEARN best practices
approach to eliminating waste in the process. How to launch KAIZEN
How to involve 100% employees in Kaizen
Kaizen builds up quality culture in the How to create an infrastructure for Kaizen
organisation by involving all employees in How to measure the benefits of Kaizen
continual improvement process focuses on What are six levels of Kaizen continual
small, small improvements in day to day basis improvement process towards world class
organisation
How to conduct ‘Kaizen Events’
How to plan for ‘Kaizen Events’
How to get buy-in from top management
KAIZEN PROFESSIONAL CERTIFICATION
CRITERIA
Completion of training
Test Score >70%

10. Quality Circle - 2 Days
INTRODUCTION. COURSE DURATION PROGRAM CONTENTS
2 days Origin and objectives of QC
teams that follow a standard process of WHO SHOULD ATTEND 10 elements of successful QC
problem identification, root cause analysis, Managers, Process Engineers, change agents, Infrastructure set up for QC
problem solving and implementation. In Roles of coordinator, facilitator,
Quality Circle - Course Overview
Lean Six Sigma practitioners, people at shop
Japanese firms there is a greater focus on floor or others that desire an understanding of leader and team members
statistical quality control, employees meet on Quality Circle methodology How to conduct QC meetings ?
own time and discuss on their own issues and COURSE INCLUDES QC and personal growth
identify solutions on the issues. In Japan it is Training Handouts Problem solving tools and
also called as Quality Control Circle (QCC) Training Completion Certificate methodology
Certified Quality Circle professional Identification of problem
Program Details
Quality Circle builds up quality Prioritisation of problem
culture in the organisation by involving all WHAT YOU WILL LEARN Defining problem
employees in continual improvement process How to set up infrastructure for Quality Circle Analysis of problem
focuses on small improvements in day to day How to get commitment from management Identification of root causes
basis. Management coordinate and facilitate and employees Developing solution
the activities of Quality Circle. To enhance the How to involve employees in continual Resistance management
effectiveness of Quality Circle, one middle improvement process Implementation of solution
management person should act as a facilitator How to select QC projects Benefit validation
for each Quality Circle. It’s a great tool to How to conduct QC meetings Follow up and review
motivate and empower employees at shop What is the QC problem solving methodology Evaluation criteria of QCFI for
floor. How to validate the benefits and sustain it national and international
What are the criteria of evaluation to competitions
participate in national and internation Workshop
competitions Case studies
How the initiative is deployed in other
organisations
QUALITY CIRCLE PROFESSIONAL
CERTIFICATION CRITERIA
Completion of training
Test Score >70%

11. Measurement System Analysis - 1 Day
INTRODUCTION. COURSE DURATION PROGRAM CONTENTS
A Measurement System Analysis, 1 day Introduction
abbreviated as MSA, is a specially designed WHO SHOULD ATTEND Gause R & R vs MSA
experiment that seeks to identify the Managers, People from Quality Control, R & X Bar- R chart
components of variation in the measurement. D,QA, Process Engineers, change agents, Lean ANOVA
Just as processes that produce a product may Six Sigma practitioners or others that desire an Components of a measurement
vary, the process of obtaining measurements understanding of MSA methodology system
and data may have variation and produce COURSE INCLUDES Planning for MSA
MSA - Course Overview
defects. A Measurement Systems Analysis Training Handouts Sampling methodology
evaluates the test method, measuring Training Completion Certificate Stability error
instruments, and the entire process of obtaining Minitab software application Discrimination error
Program Details
measurements to ensure the integrity of data Certified Measurement System Analyst Linearity error
used for analysis and to understand the Repeatability & Reproducibility
implications of measurement error for decisions WHAT YOU WILL LEARN Accuracy vs Precision
made about a product or process. MSA is an Why we need MSA? Precision to Tolerance ratio
important element of Six Sigma methodology What is relationship between MSA & process Minitab software application
and of other quality management systems. improvement? No. of distinct catagories
MSA analyzes the collection of equipment, What are different types of MSA? Study variation
operations, procedures, software and What are various types of measurement Error %age contributed my
personnel that affects the assignment of a errors? measurement system
number to a measurement characteristic. A How to quantify those errors ? Workshop
Measurement Systems Analysis considers the How to eliminate those errors ? Case studies
following: selecting the correct measurement What are the pre-cautions need to be taken to
and approach, assessing the measuring avoid those errors ?
device, assessing procedures & operators,
assessing any measurement interactions, and MEASUREMENT SYSTEM ANALYST
calculating the measurement uncertainty of CERTIFICATION CRITERIA
individual measurement devices and/or
measurement systems. Completion of training
Test Score >70%

12. Process Capability Study - 1 Day
Process Capability Study - Course Overview
INTRODUCTION. COURSE DURATION PROGRAM CONTENTS
Over a period of time inefficiencies built into 1 day Introduction
each and every process. Hence measurement WHO SHOULD ATTEND Pre-requisite of capability study
of Process Capability for each and every Managers, Process Engineers, change agents, Understand Voice of the Customer
process at a regular interval is very essential . Lean Six Sigma practitioners or others that (VOC)
This also help to increase efficiency and desire an understanding of process capability Understand Voice of the Process
improve the process on regular basis. methodology (VOP)
COURSE INCLUDES Process Capability (Cp)
Process capability Studies are conducted Training Handouts Process Capability Index (Cpk)
to obtain early information on the performance Training Completion Certificate Capability vs Performance
of new or revised processes relative to internal Minitab software application Relationship between Cp , Cpk & Pp,
Program Details
or customer requirements. In many cases, Certified Process Capability Analyst Ppk
preliminary studies should be conducted at WHAT YOU WILL LEARN Sigma level of process
several points in the evolution of new What is Voice of Customer (VOC)? Minitab software applications
processes (e.g., at the equipment or tooling What is Voice of Process (VOP) ? Process Capability for attribute data
subcontractor's plant, after installation at the How to measure capability of the process ?
supplier's plant) These studies should be based What is the potential capability of the
on as many measurements as possible. process?
What are short term and long term capability
Chinese Proverb : of process ?
If you don’t know where you are going, any Can we meet customer’s requirement with
road will do. current process capability?
Humphrey Proverb : Do we need investment to enhance
If you don’t know where you are, a map process capability and satisfy customer ?
What is current sigma level and defect level of
won’t help.
the process ?
What actions we need to take to enhance
process capability ?
PROCESS CAPABILITY ANALYST
CERTIFICATION CRITERIA
Completion of training
Test Score >70%

13. Quality Function Deployment (QFD) - 1 Day
INTRODUCTION. COURSE DURATION PROGRAM CONTENTS
QFD was first conceptualized in 1966 as a 1 day Introduction
method or concept for new product WHO SHOULD ATTEND Tools to capture voice of the
development under the umbrella of Total Managers, Design engineers, People from Sales customer
Quality Control, hinshitsu tenkai (quality & Marketing, R & D, Process Engineers, change House of quality
deployment) and was developed by Dr. Shigeru agents, Lean Six Sigma practitioners or others QFD & Quality table
Mizuno and Yoji Akao. The Japan Society of that desire an understanding of Quality Function Required items to required quality
Quality Control formed a research group to Deployment methodology Quality deployment table
QFD - Course Overview
specifically study Quality Function Deployment COURSE INCLUDES Quality element deployment table
(QFD) in 1978. QFD is used to translate Training Handouts Planned Quality vs Design Quality
customer requirements to engineering Training Completion Certificate Benchmarking
Program Details
specifications. It is a link between customers - Certified QFD Professional Target setting for development &
design engineers - competitors -manufacturing. WHAT YOU WILL LEARN Improvement
It provides an insight into the whole design and What is Voice of Customer (VOC)? Survey for troubles and claims
manufacturing operation from concept to How to capture VOC ? Survey for current technology and
manufacture and it can dramatically improve How to convert language of customer to equipment
the efficiency as production problems are processl language or Critical to Quality (CTQ) Selection of technology tasks
resolved early in the design phase. parameters Resolution of technology task
What is house of Quality ? Rewrite Quality table
It is very powerful as it incorporates the Steps to prepare house of Quality ? Quality Assurance characteristics
voice of the customer in the designs - hence it How to built quality into the product right in Process planning
is likely that the final product will be better design stage ? QC Process chart
designed to satisfy the customer's needs. How to make product /service right at the first Standard Operating Procedure
Moreover, it provides an insight into the whole time ? Benefits
design and manufacturing operation (from How to bring in ‘ZERO’ defect concept to
concept to manufacture) and it can dramatically process ?
improve the efficiency as production problems
are resolved early in the design phase. QFD PROFESSIONAL CERTIFICATION
CRITERIA
Completion of training
Test Score >70%

14. KANO Analysis - 1 Day
INTRODUCTION. COURSE DURATION PROGRAM CONTENTS
In the late 1970s Dr. Noriaki Kano of Tokyo 1 day Introduction to KANO analysis
Rika University further refined the notion of WHO SHOULD ATTEND KANO Model
quality derived partially from his study of Managers, Design engineers, People from R & Value & Value stream
KANO Analysis - Course Overview
Herzberg's "Motivator-Hygiene Theory" and re- D, Process Engineers, change agents, Lean Six Reactive vs Proactive mode of voice
defined quality along two dimensions in Sigma practitioners or others that desire an of the customer
contrast to the linear "good-bad" "ok-not ok" understanding of process capability KANO survey
dimension in existence all along. The two methodology Designing questionnaire
dimensions were: 1) the degree to which a COURSE INCLUDES Conduct survey
product or service performs, & 2) the degree to Training Handouts Analysis of the survey
which the user is satisfied. The correlation of Training Completion Certificate Preparation of Multi Generation
Program Details
quality on two axes further led to three unique Certified KANO Analysis Professional Product Plan ( MGPP)
definitions of quality, namely: WHAT YOU WILL LEARN Integration with process parameters
How to determine value to customer? through QFD
• Must-be requirements of Customer What is Value & Value stream ? Workshop
( Basic quality) What are various types of customer Case Studies
• One Dimentional requirements of requirements ?
Customer (Performance quality) How best we can capture requirements of
• Delighter requirements of Customer customer ?
(Excitement quality) How to conduct survey ?
How to analyse results & take action ?
This analysis is useful to capture voice of the How to integrate VOC (Voice of Customer)
customer , various types of customer with VOP(Voice of process) & VOD (Voice of
requirements . KANO analysis helps us to in design)
product/service design and preparing Multi
Generation Product Plan (MGPP) KANO ANALYSIS PROFESSIONAL
CERTIFICATION CRITERIA
Completion of training
Test Score >70%

15. Design of Experiment (DOE)- 3 Days
INTRODUCTION. COURSE DURATION PROGRAM CONTENTS
DOE is a systematic approach of investigation of 3 days
a system or process. A series of structured tests WHO SHOULD ATTEND Introduction to DOE
are designed in which planned changes are made Managers, Process Engineers, R & D people, One factor at a time (OFAT)
to the input variables of a process or system. The change agents, Lean Six Sigma practitioners, or Fractional factorial design
effects of these changes on a pre-defined output others that desire an understanding of DOE Aliasing
are then assessed methodology Fractional factorial design
. COURSE INCLUDES Placket Burman design
DOE - Course Overview
Training Handouts Blocking
DOE is important as a formal way of Training Completion Certificate Centre point
maximizing information gained while resources Certified DOE professional Response Surface Design (RSD)
Program Details
required. DOE can be used to find answers in WHAT YOU WILL LEARN Mixture design
situations such as "what is the main contributing How to find out ‘Vital few’ causes from ‘Trivial Orthogonal Array(OA) design
factor to a problem?", "how well does the Many’ scientifically ? Taguchi robust design
system/process perform in the presence of How to exactly identify the effect of factors on Other optimisation techniques
noise?", "what is the best configuration of factor responses ?
values to minimize variation in a response?" etc. How to identify the effect of interaction
In general, these questions are given labels as between the factors on responses ?
particular types of study. In the examples given How to plan for a DOE ?
above, these are problem solving, parameter How to execute DOE ?
design and robustness study. Which type of DOE need to be selected for
which problem ?
How to optimise factor settings to get
maximum output ?
How to optimise the composition of the
mixture/solution to get maximum response ?
How to set parameters to design a robust
process ?
DOE PROFESSIONAL CERTIFICATION
CRITERIA
Completion of training
Test Score >70%

16. Failure Mode & Effect Analysis (FMEA)- 1 Day
INTRODUCTION. COURSE DURATION PROGRAM CONTENTS
Failure Mode and Effects Analysis is a 3 days
systematic technique which identifies and ranks WHO SHOULD ATTEND Introduction to FMEA
the potential failure modes of a design or a Managers, Process Engineers, R & D people, FMEA and it’s applications
process in order to prioritize improvement change agents, Lean Six Sigma practitioners, or Types of FMEAs
Actions others that desire an understanding of FMEA Steps to make FMEA
methodology Process Mapping
FMEA is an important analysis tool bacause COURSE INCLUDES Controllable and Noise factor
FMEA - Course Overview
– Training Handouts Potential failure modes
Training Completion Certificate Effect of failure
• It is used to predict and prevent process Certified FMEA professional Determination of causes of failure
Program Details
defects WHAT YOU WILL LEARN Various levels of control in process
How to pre-screen process inputs for problem Risk Priority Number (RPN)
• It helps in predicting process faults before a solving ? Rating scale for Severity, Occurance
change is made or before a process is started How to identify quick hit actions ? & Detectability
How to identify potential failure modes in Action planning
• It is most helpful in process development stage process/design ? Post RPN
, even before the process is begun How to prioritise risk mitigation efforts ? Design FMEA
How FMEA can be used for new product Process FMEA
/process design ?
How FMEA can be used to solve problems in
existing process ?
FMEA PROFESSIONAL CERTIFICATION
CRITERIA
Completion of training
Test Score >70%

17. 5S WORKSHOP - 2 Days
INTRODUCTION. COURSE DURATION PROGRAM CONTENTS
5S is a Japanese concept of better workplace 2 days
management, comprises of following 5 Ss. WHO SHOULD ATTEND Introduction
Seiri (sort), Seiton (set in order), Seiso Managers, Process Engineers, change agents, Preparation for 5S
(shine), Seiketsu (standardize), Shitsuke Lean Six Sigma practitioners,Shop floor people Infrastructure for 5S
(sustain) or others that desire an understanding of 5S Sorting
methodology Set in order
The 5S - Campaign is a common action for COURSE INCLUDES Shining
everyone to create tidy and clean working area. Training Handouts Standardising
5S - Course Overview
The objectives of 5S are – Training Completion Certificate Sustaining
• Creation of a clean and more pleasant work Certified 5S professional 5 levels of 5S
Program Details
environment WHAT YOU WILL LEARN 5S audit
• Creation of space and reduction of How to make our workplace spic & span all Workshop
archiving the time ? Case studies
costs How to do preparation for 5S deployment
• Reduction of unnecessary searching How to set up infrastructure for 5S
times for sustainance
material, documents, etc. How to involve top management in 5S ?
Advantages of 5S are - How to involve employee for 5S sustainance ?
• Quicker recognition and elimination of How to do documents management ?
wastes How to create a clean productive work place
• Reduction of disturbances to motivate employees at shop floor ?
• Employees feel better on the job
• Work environment is presentable to 5S PROFESSIONAL CERTIFICATION
customers at any time CRITERIA
Completion of training
Test Score >70%

18. Value Stream Mapping (VSM) - 1 Day
INTRODUCTION. COURSE DURATION PROGRAM CONTENTS
Value Stream Map is a visual tool 1 day
used to document the flow of products or WHO SHOULD ATTEND Introduction to VSM
ser vices through a system. The VSM Managers, Process Engineers, change agents, Hierarchy of process discovery
differentiates the value-adding activities of a Lean Six Sigma practitioners,Shop floor people Product/Service family
system from the non-value-adding ones. or others that desire an understanding of VSM Scoping of VSM
Recording the time taken for each activity shows methodology Components of VSM
what percentage of valuable time an object or Steps to prepare VSM
VSM - Course Overview
person spends in a system. Any non-value- COURSE INCLUDES Current state map
adding time indicates an opportunity for possible Training Handouts Future state map
improvement within the system. Training Completion Certificate Opportunities for Improvement
Program Details
Certified VSM professional Implementation plan
Workshop
The VSM shows the process flow from WHAT YOU WILL LEARN Case stydies
order to delivery and includes - a) information & How value is flowing across the supply chain ?
material flow, b) product throughput & cycle How product/service flow is happening in
times, c) resources utilized, d) value added times process?
and e) location of significant waste . It helps in How information flow is happening in the
identifying potential improvement projects need organisation ? How to optimise ?
to be taken up to enhance efficiency and What is current state of the process ?
effectiveness of the processes. What should be the future state of the
process?
How to establish flow, reduce inventory,
enhance value added percentage in the
process?
VSM PROFESSIONAL CERTIFICATION
CRITERIA
Completion of training
Test Score >70%

19. Problem Solving Tools - 2 Days
INTRODUCTION. COURSE DURATION PROGRAM CONTENTS
Problem Solving Tools - Course Overview
In any business endeavor, there 2 days
are various processes working simultaneously to WHO SHOULD ATTEND Introduction to problem
achieve a certain desired business objectives. Managers, Process Engineers, change agents, Problem definition
Any deviation in the outcome of those processes Lean Six Sigma practitioners,Shop floor people 8D approach
from the desired outcome can be considered as or others that desire an understanding of Check sheet
a defect or a failure or an event or a problem. problem solving tools Pareto chart
Cause and effect diagram
For every problem, there is at least COURSE INCLUDES Graph & Control Charts
one simple, plausible and wrong solution. There Training Handouts Scatter plot
are no ‘quick fixes’ to any problem.Quick fixes Training Completion Certificate Histogram
Program Details
normally results in complacency and false Certified Quality tools professional Stratification
security of having cured problem. Thus every Afinity diagram
problem needs to be solved in a scientific and WHAT YOU WILL LEARN Force field analysis
s y s t e m a t i c m a n n e r . How to identify a problem ? Matrix diagram
How to prioritise the problems ? Process Decision Programme Chart
How to understand the problem ? Interrelationship digraph
What are various basic problem solving tools? Nominal Group Technique
What are various management tools ? Tree Diagram
What methodology we need to follow to solve
the problem ?
QUALITY TOOLS PROFESSIONAL
CERTIFICATION CRITERIA
Completion of training
Test Score >70%

20. Change Management - 1 Day
INTRODUCTION. COURSE DURATION PROGRAM CONTENTS
Change management is the 1 day
Change Management - Course Overview
process of developing a planned approach to WHO SHOULD ATTEND Dynamics of change
change in an organization. Typically the Top Management, Managers, Process Change model
objective is to maximize the collective benefits Engineers, change agents, Lean Six Sigma Steps for leading change
for all people involved in the change and practitioners, or others that desire an Establish sense of urgency
minimize the risk of failure of implementing the understanding of Change management Create support team
change. The discipline of change management methodology Develop vision
deals primarily with the human aspect of Communication skills
change, and is therefore related to pure and COURSE INCLUDES Resistance management
i n d u s t r i a l p s y c h o l o g y Training Handouts Employee empowerment
Program Details
Training Completion Certificate Create short term wins
Change leaders that understand Certified Quality tools professional Team dynamics
the phases of transition and are able to apply
management strategies for each of the transition WHAT YOU WILL LEARN
phases accelerate the time to acceptance which How to manage change
in turn results in desired behavior. When do we need change
Is change good every time ?
What are the steps for change ?
How to make change last ?
How to plan for change ?
CHANGE MANAGEMENT PROFESSIONAL
CERTIFICATION CRITERIA
Completion of training
Test Score >70%

21. Lean Six Sigma Overview - 1 Day
INTRODUCTION. PROGRAM CONTENTS
Lean Six Sigma Overview - Course Overview
COURSE DURATION
Six sigma is a highly disciplined approach 1 day
used to reduce the process variations to the Introduction to Lean Six Sigma
extent that the level of defects are drastically WHO SHOULD ATTEND History of Lean
reduced to less than 3.4 per million opportunities Top Management, Managers, Process Histrory of Six Sigma
(DPMO). Six sigma is a powerful approach to Engineers, change agents, or others that desire Lean principles
a c h i e v e b r e a k t hr oug h im pr ovem ent s in basic understanding of Lean Six Sigma Types of waste
manufacturing, engineering and business methodology Lean Six Sigma Integration
processes. It is a new way of doing business that Lean Six Sigma deployment
would eliminate the existing defects efficiently COURSE INCLUDES methodology
and prevent defects from occurring . Training Handouts Project identification and prioritisation
Program Details
Training Completion Certificate Black Belt/Green Belt selection
Lean evaluates the entire operation Poject execution
of the factory and restructures the method in WHAT YOU WILL LEARN DMAIIC Methodology
order to reduce wasteful activities like waiting, What is Lean methodology ? Project review
transportation, material hand-offs, inventory, Can it be used for transactional processes ? Financial validation of projects
over-production, etc. It focuses on product flow What are various types of waste ? Institutionalisation of Lean Six Sigma
and operator activity i.e, how can you produce How to create improvement culture in the
the product in the least amount of time, and how organisation ?
you can standardize the operator methods and What is Six Sigma ?
g i ve t h e o p e r a t o r w h at he/ she nee ds? Brief history of Lean & Six Sigma ?
. What kind of infrastructure is required for Lean
Six Sigma deployment ?
What kind of ROI one should target for ?
How to select business critical projects ?
How to deploy Lean Six Sigma ?