Session 1: The Define Phase

• Writing problem statements
• Setting the project objectives
• Scoping the project
• Mapping the high- level process: SIPOC mapping
• Linking the problem to VOC
• Defining CTQs
• Drawing up the project charter

Session 2: Understanding the Current State Process

• Process mapping tools overview
• The role of process mapping in DMAIC projects
• Process flow & sequence charting techniques
• Identifying Value and Non-Value Add activity & identify quick wins

Session 3: Managing Change & Engaging Stakeholders

• Analysing enablers/barriers using force field analysis
• Building and communicating the business case
• Securing project sponsorship & engaging key stakeholders
• Influencing skills & dealing with initial resistance
• Building and managing the project team

Session 4: Managing & Defining Black Belt Projects

• DMAIC versus DMADV projects
• Scoping complex cross-functional projects
• Value stream mapping as a scoping tool
• Aligning the project to business strategy
• Managing project reviews (tollgates)
• Considering project risks

Session 5: Value Stream Mapping

• Introduction to Value Stream Mapping
• Creating a Current State Map
• Using VSM as a Scoping Tool
• Identifying the Opportunities

Session 6: Data Collection

• The role of data collection planning throughout a DMAIC project
• Use of Is/Is Not to find gaps in knowledge
• Understanding variation
• Selecting what to measure
• Calculating sample size
• Sampling considerations
• Developing a robust data collection plan
• Guidelines for survey sampling

Session 7: Measurement  System Analysis

• MSA fundamentals
• Type 1 studies for repeatability
• Type II studies (reproducibility)
• Nested gauge R&Rs for destructive tests
• Assessing linearity & bias aspects of calibration
• Assessing stability (of bias during calibration)
• Attribute agreement analysis for pass/fail judgements

Session 8: Process Capability & Process Control

• Assessing process control
• Anatomy & use of control charts
• Applications of SPC charts for variable and attribute data
• Understanding process capability
• Calculating process capability for continuous and attribute data
• Selecting appropriate capability metrics & indices

Session 9: Advanced Statistical Approaches

• Understanding probability distributions for variable and attribute data
• Dealing with non- normal data
• Capability analysis for non-normal data
• Statistical process control charts for non-normal data
• The central limit theorem
• Understanding and using data transformations

Session 10: Analyse Phase

• Verifying the root cause
• Taking a structured approach to data analysis
• Links to the cause and effect diagram
• 5 Why approach to problem solving
• Box plots & scatter diagrams
• Significance testing approach
• Tips for summarising and presenting the analysis

Session 11: Hypothesis Testing

• Use of inferential statistics
• Writing a hypothesis statement
• Setting a confidence level
• Understanding the P-Value
• Tests for variable and attribute data
• Power & sample size
• Non-parametric techniques

Session 12: Intro to DOE

• Overview of DOE techniques
• Optimisation challenge
• Applications of DOE techniques

Session 13: Optimising the Process

• Regression analysis
• Understanding correlation
• Introduction to simple linear regression
• Introduction to multiple regression

Session 14: Screening & Taguchi Methods

• Introduction to fractional factorial
• Screening designs
• Advanced techniques e.g. EVOP, RSM
• Taguchi loss function
• Taguchi designs that deliver robust solutions in the presence of noise

Session 15: Advanced DOE Techniques

• Mixed and multi-level designs
• Response surface designs
• Botched runs
• Randomisation and grey coding
• DOE with historical data

Session 16: Situational Leadership

• Transformational leadership
• Influencing change
• Concepts and models for change
• Persuasion campaigning

Session 17: Managing Resistance & Embedding Change

• Learning from experience
• Emotional responses to change
• Rationalising resistance to change
• Handling conflict
• Sustaining change through the Improve & Control phases – and beyond
• Facilitating handover

Session 18: Develop the Improvement

• Taking a structured approach for the improve phase
• Use of creativity tools to generate alternative solutions
• Developing & evaluating alternative solutions
• Developing the future state map
• Verifying & implementing the solution

Session 19: Coaching Improvement Teams

• The key skills of coaching
• The coaching continuum expert to discovery
• Using the GROW model

Session 20: Implementing Control

• Key steps of the Control phase
• Confirming the improvement
• Developing a control plan
• Different types of process control
• The principle of mistake proofing
• Monitoring effectiveness
• Closing the improvement project