Lean Six Sigma Yellow & Orange Belt Exercise Book

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)