Lecture 1 ..................................................................................................................................... 5
The hidden factory ................................................................................................................. 7
LSS from a strategic perspective ........................................................................................ 8
Value proposition: strategic benefits ................................................................................. 8
Methodology .......................................................................................................................... 9
Scientific method................................................................................................................ 9
DMAIC Method................................................................................................................... 9
Organizational structure: Lean Six Sigma organization – Project management/executio .. 10
Summary: ............................................................................................................................. 12
DEFINE .................................................................................................................................. 13
Project selection – p.34 .................................................................................................... 13
Project Charter ..................................................................................................................... 13
Team meetings ......................................................................................................................... 15
A decision procedure, roles, and managing a meeting .................................................... 16
The stakeholder analysis ...................................................................................................... 17
Summary .............................................................................................................................. 18
Lecture 2 ................................................................................................................................... 19
DMAIC1: Define the CTQs .................................................................................................... 19
Critical to Quality (CTQ) ........................................................................................................ 20
Industry / industries where most LSS projects take place ............................................... 21
Operational Definition.......................................................................................................... 22
Measurement plan ............................................................................................................... 23
Measurement form: ......................................................................................................... 23
DMAIC2: validate the measurement procedures. ............................................................... 24
1. Validate the measurement procedures ....................................................................... 24
2. Measurement error ...................................................................................................... 25
3. Measurement system analysis ..................................................................................... 26
Gage R&R studies (numerical).......................................................................................... 26
Agreement studies (categorical data / nominal data) ..................................................... 29
Lecture 3 ................................................................................................................................... 31
Lean wastes .......................................................................................................................... 31
Implementing Lean: Mura-ri-da ........................................................................................... 32
Value stream map (VSM) ..................................................................................................... 34
Lean and Fat processes: WIP control ................................................................................... 35
DMAIC3: Diagnose the current process ............................................................................... 38
1
, Data organization / Organize the data ................................................................................. 38
Diagnose the current performance ...................................................................................... 38
Control charts ................................................................................................................... 39
Control charts: Box-Cox transformation .......................................................................... 40
Process capability analysis (PCA)...................................................................................... 40
PCA in services .................................................................................................................. 43
Redefine the project’s objectives ......................................................................................... 45
Lecture 4 ................................................................................................................................... 46
DMAIC4: Identify potential influence factors (idea generation/influences) ....................... 46
Influence factors: types of Xs ............................................................................................... 46
Process matrix ...................................................................................................................... 46
Methods to find influence factors: using data, with your team, or using Lean ................... 47
1. Using Data ................................................................................................................ 47
2. With your team ........................................................................................................ 48
Expert knowledge ............................................................................................................. 48
Analogous processes ........................................................................................................ 48
Brainstorming ................................................................................................................... 49
3 Open discussion without rigid structure: ...................................................................... 49
Focus too narrow: ............................................................................................................ 49
Vague and Evasive theories.............................................................................................. 50
Conditioning ..................................................................................................................... 50
Failure mode and Effect analysis (FMEA) ......................................................................... 51
3. Using Lean Principles .................................................................................................... 52
DMAIC5: Establish the effect of influence factors ............................................................... 54
Types of X’s ....................................................................................................................... 54
Effect and changeability ....................................................................................................... 54
Types of evidence ............................................................................................................. 55
Waterfall or step chart ......................................................................................................... 56
Lecture 5 ................................................................................................................................... 58
DMAIC6: Design improvement actions ................................................................................ 58
Determine the improvement direction ................................................................................ 58
Streamlining and line balancing ........................................................................................... 59
Proposing improvement actions ...................................................................................... 60
Advanced Lean ......................................................................................................................... 64
Process analytics .................................................................................................................. 64
2
, Process variability ................................................................................................................. 65
Process planning & control .................................................................................................. 67
Push vs. pull control ......................................................................................................... 67
Make to order (MTO) vs. Make to stock (MTS)................................................................ 67
1-piece vs. batch flow ....................................................................................................... 68
Bottleneck optimization (Theory Of Constraints TOC) ........................................................ 69
Final guidelines for advanced Lean ...................................................................................... 70
Lecture 6 ................................................................................................................................... 72
DMAIC 7: Improve process control ...................................................................................... 72
Organize normal work .......................................................................................................... 72
Failure mitigation: failures can still occur after improvements. .......................................... 73
Incidents handling ................................................................................................................ 75
Incidents handling line management ............................................................................... 76
Projects for chronic problems: chronic = potentially project for LSS .................................. 77
DMAIC8: Close the project ................................................................................................... 78
Project closure .................................................................................................................. 78
Discharge of a LSS project .................................................................................................... 79
Organization ..................................................................................................................... 79
Time lines ......................................................................................................................... 79
Discharge form ................................................................................................................. 80
Follow ups ........................................................................................................................ 80
Statistical process monitoring .................................................................................................. 81
Statistical process monitoring (SPM) ................................................................................... 81
Introduction...................................................................................................................... 81
Stepwise procedure for SPM ................................................................................................ 82
SPM control loops ................................................................................................................ 84
EWMAA control chart: to identify sustained patterns in the mean. ............................... 84
EWMA control charts ....................................................................................................... 85
CUSUM control chart ........................................................................................................... 86
Seminar 1: Data ........................................................................................................................ 88
Numerical data: boxplot, histogram, descriptive statistics.................................................. 88
Categorical data: elementary statistical tools...................................................................... 90
Seminar 2.................................................................................................................................. 92
Seminar 4.................................................................................................................................. 95
Hypothesis testing ................................................................................................................ 95
3
, Method of data analysis ....................................................................................................... 95
ANOVA .................................................................................................................................. 95
ANOVA interpretation ...................................................................................................... 96
Kruskal-Wallis Procedure ................................................................................................. 99
2-Sample T-test: compare means .................................................................................... 99
2-Sample t-test: test for equal variances ......................................................................... 99
2-Sample t-test: Mann-Whitney test ............................................................................... 99
Regression analysis............................................................................................................. 100
Chi-square test ................................................................................................................... 102
Logistic Regression ............................................................................................................. 102
Seminar 5................................................................................................................................ 104
Design analysis of experiments. ......................................................................................... 104
Factorial design: 2-level experiments with more factors. ............................................. 104
Factorial plots ..................................................................................................................... 105
Error variance of an experiment ........................................................................................ 105
Replication and centre point of factorial design ................................................................ 106
2-Level experiments with more factors: 2^3 design. ......................................................... 107
Summary of factorial design .............................................................................................. 109
4
The hidden factory ................................................................................................................. 7
LSS from a strategic perspective ........................................................................................ 8
Value proposition: strategic benefits ................................................................................. 8
Methodology .......................................................................................................................... 9
Scientific method................................................................................................................ 9
DMAIC Method................................................................................................................... 9
Organizational structure: Lean Six Sigma organization – Project management/executio .. 10
Summary: ............................................................................................................................. 12
DEFINE .................................................................................................................................. 13
Project selection – p.34 .................................................................................................... 13
Project Charter ..................................................................................................................... 13
Team meetings ......................................................................................................................... 15
A decision procedure, roles, and managing a meeting .................................................... 16
The stakeholder analysis ...................................................................................................... 17
Summary .............................................................................................................................. 18
Lecture 2 ................................................................................................................................... 19
DMAIC1: Define the CTQs .................................................................................................... 19
Critical to Quality (CTQ) ........................................................................................................ 20
Industry / industries where most LSS projects take place ............................................... 21
Operational Definition.......................................................................................................... 22
Measurement plan ............................................................................................................... 23
Measurement form: ......................................................................................................... 23
DMAIC2: validate the measurement procedures. ............................................................... 24
1. Validate the measurement procedures ....................................................................... 24
2. Measurement error ...................................................................................................... 25
3. Measurement system analysis ..................................................................................... 26
Gage R&R studies (numerical).......................................................................................... 26
Agreement studies (categorical data / nominal data) ..................................................... 29
Lecture 3 ................................................................................................................................... 31
Lean wastes .......................................................................................................................... 31
Implementing Lean: Mura-ri-da ........................................................................................... 32
Value stream map (VSM) ..................................................................................................... 34
Lean and Fat processes: WIP control ................................................................................... 35
DMAIC3: Diagnose the current process ............................................................................... 38
1
, Data organization / Organize the data ................................................................................. 38
Diagnose the current performance ...................................................................................... 38
Control charts ................................................................................................................... 39
Control charts: Box-Cox transformation .......................................................................... 40
Process capability analysis (PCA)...................................................................................... 40
PCA in services .................................................................................................................. 43
Redefine the project’s objectives ......................................................................................... 45
Lecture 4 ................................................................................................................................... 46
DMAIC4: Identify potential influence factors (idea generation/influences) ....................... 46
Influence factors: types of Xs ............................................................................................... 46
Process matrix ...................................................................................................................... 46
Methods to find influence factors: using data, with your team, or using Lean ................... 47
1. Using Data ................................................................................................................ 47
2. With your team ........................................................................................................ 48
Expert knowledge ............................................................................................................. 48
Analogous processes ........................................................................................................ 48
Brainstorming ................................................................................................................... 49
3 Open discussion without rigid structure: ...................................................................... 49
Focus too narrow: ............................................................................................................ 49
Vague and Evasive theories.............................................................................................. 50
Conditioning ..................................................................................................................... 50
Failure mode and Effect analysis (FMEA) ......................................................................... 51
3. Using Lean Principles .................................................................................................... 52
DMAIC5: Establish the effect of influence factors ............................................................... 54
Types of X’s ....................................................................................................................... 54
Effect and changeability ....................................................................................................... 54
Types of evidence ............................................................................................................. 55
Waterfall or step chart ......................................................................................................... 56
Lecture 5 ................................................................................................................................... 58
DMAIC6: Design improvement actions ................................................................................ 58
Determine the improvement direction ................................................................................ 58
Streamlining and line balancing ........................................................................................... 59
Proposing improvement actions ...................................................................................... 60
Advanced Lean ......................................................................................................................... 64
Process analytics .................................................................................................................. 64
2
, Process variability ................................................................................................................. 65
Process planning & control .................................................................................................. 67
Push vs. pull control ......................................................................................................... 67
Make to order (MTO) vs. Make to stock (MTS)................................................................ 67
1-piece vs. batch flow ....................................................................................................... 68
Bottleneck optimization (Theory Of Constraints TOC) ........................................................ 69
Final guidelines for advanced Lean ...................................................................................... 70
Lecture 6 ................................................................................................................................... 72
DMAIC 7: Improve process control ...................................................................................... 72
Organize normal work .......................................................................................................... 72
Failure mitigation: failures can still occur after improvements. .......................................... 73
Incidents handling ................................................................................................................ 75
Incidents handling line management ............................................................................... 76
Projects for chronic problems: chronic = potentially project for LSS .................................. 77
DMAIC8: Close the project ................................................................................................... 78
Project closure .................................................................................................................. 78
Discharge of a LSS project .................................................................................................... 79
Organization ..................................................................................................................... 79
Time lines ......................................................................................................................... 79
Discharge form ................................................................................................................. 80
Follow ups ........................................................................................................................ 80
Statistical process monitoring .................................................................................................. 81
Statistical process monitoring (SPM) ................................................................................... 81
Introduction...................................................................................................................... 81
Stepwise procedure for SPM ................................................................................................ 82
SPM control loops ................................................................................................................ 84
EWMAA control chart: to identify sustained patterns in the mean. ............................... 84
EWMA control charts ....................................................................................................... 85
CUSUM control chart ........................................................................................................... 86
Seminar 1: Data ........................................................................................................................ 88
Numerical data: boxplot, histogram, descriptive statistics.................................................. 88
Categorical data: elementary statistical tools...................................................................... 90
Seminar 2.................................................................................................................................. 92
Seminar 4.................................................................................................................................. 95
Hypothesis testing ................................................................................................................ 95
3
, Method of data analysis ....................................................................................................... 95
ANOVA .................................................................................................................................. 95
ANOVA interpretation ...................................................................................................... 96
Kruskal-Wallis Procedure ................................................................................................. 99
2-Sample T-test: compare means .................................................................................... 99
2-Sample t-test: test for equal variances ......................................................................... 99
2-Sample t-test: Mann-Whitney test ............................................................................... 99
Regression analysis............................................................................................................. 100
Chi-square test ................................................................................................................... 102
Logistic Regression ............................................................................................................. 102
Seminar 5................................................................................................................................ 104
Design analysis of experiments. ......................................................................................... 104
Factorial design: 2-level experiments with more factors. ............................................. 104
Factorial plots ..................................................................................................................... 105
Error variance of an experiment ........................................................................................ 105
Replication and centre point of factorial design ................................................................ 106
2-Level experiments with more factors: 2^3 design. ......................................................... 107
Summary of factorial design .............................................................................................. 109
4
