Lean-Six Sigma Training Programme

Dr David Scrimshire commented: “back in 2005 I wanted to create a super-effective way in which to qualify Six Sigma Belts in as short a time as possible for the aerospace and defence sectors” and incorporate the tools and approaches of Lean Manufacturing. “So, I used the principles and practices of Accelerated Learning to devise a programme which could deliver the knowledge in a manner that would be easily to grasp by students and immediately put to work to the benefit of their organizations”.

Many SC21 signatories have used the Lean Six Sigma Training Programme to address major projects identified in their CSIP. These 'break-through' dramatically upgrade the people skills and deliver substantial improvements in organization performance in the areas of quality and delivery.

TEC Transnational’s Lean Six Sigma Training Programme consists of a series of 1‑day and 2-day tutor-led training sessions following the D-M-A-I-C cycle - delivered on a monthly basis. Each session contains exercises and ‘homework’ sessions to ensure that the principles and practices are fully understood. In parallel, students undertake individual ‘break-through’ projects to ensure that their newly acquired skills are put to use immediately to the benefit of their organizations – “achieving excellence through accelerated learning”!

Each of the tutor-led courses is highly interactive and uses worked examples and group exercises to illustrate the principles, methodologies and statistics involved. TEC use and recommend Minitab(R) statistical software.

The on-site programme can be delivered at any time. The next 'Public' programme commences in first quarter 2018.

The practical training is delivered as tutor-led sessions (1-day and 2-day) scheduled over five to six months to maximize the benefits and minimize any disruption to routine work activities.

The break through project activities commence after the Recognise/Define step and serve to support and accelerate the progress of learning for the individuals involved and maximize their organization’s return on its investment. Each training session contains ‘hands-on’ exercises focused on the selected topics so that learning and competency can be assessed and any individual ’skills gaps’ can be recognised and addressed immediately.

The programme syllabus includes the following topics –

Recognise/Define:

  • Introduction to basic statistics
  • Developing the business case
  • Identifying key stakeholders
  • House of quality
  • Stakeholder analysis
  • Voice of the customer
  • Critical to ‘X’ (CTX)
  • Verifying CTXs
  • Identify and segment
  • High level process map
  • Project charter
  • Project plan
  • Applicable lean manufacturing topics

Measure:

  • Understanding variability
  • Measurement basics
  • Measurement process and plan
  • Selecting measures
  • Data definition and sources
  • Sampling techniques
  • Measuring yield and capability
  • Implementing the measure plan
  • The ‘hidden factory’
  • Applicable lean manufacturing topics

Analyse:

  • Working with different data ‘types’
    • Continuous
    • Count
    • Attribute
  • Understanding probability distributions
    • Binomial
    • Poisson
    • Exponential
    • Normal
  • Understanding how probability distribution models are created
  • Major distributions
    • Discrete
    • Continuous
  • Visualizing probability distributions
  • Matching a probability distribution to a particular context
  • Understanding the ‘flow’ o the Analyse Step
  • Refine problem definition – look at the source (Genba)
  • Process mapping, analysis and control
  • Looking for trends and patterns with basic statistical analysis
    • Mean, Median, Mode
    • Regression and correlation analysis
    • Graphical techniques for data display
  • Introduction to the comparison of processes
  • Understanding population and samples
    • parameters and ‘statistics’
    • central limit theorem
    • probabilities
  • Fundamentals of hypothesis testing
  • Hypothesis testing for AVERAGES
    • central tendency
    • mean, median and mode
    • z-tests
    • t-tests (1-sample & 2-sample)
    • One-way ANOVA
  • Hypothesis testing for STANDARD DEVIATIONS
  • Measuring and confirming process improvement
    • special causes
    • common causes
  • Applicable lean manufacturing topics

Improve:

  • Brain storming techniques
  • Understand the process approach
  • Lean principles and practices
  • Optimising flow
  • Rapid changeover (SMED)
  • Introduction to Kanban
  • Visual management techniques
  • Developing solution options
  • Choosing between possible solutions
  • Facilitating kaizen events and improvements teams
  • FMEA and FTA (risk analysis)
  • Project implementation planning
  • Applicable lean manufacturing topics

Control:

  • Documentation - the 'KISS principle'
  • Poke Yoke (mistake proofing)
  • Statistics process control (SPC)
  • Process management
  • Team Charts and ‘Storyboards’
  • Writing a Six Sigma Project
  • Applicable lean manufacturing topics

The individual ‘break-through’ projects are agreed with a senior member of the organization’s staff, which are documented in a Project Charter.

Public course

Our public courses are run at the Woodland Grange Conference Centre in Warwickshire

The course fee includes a 3-course lunch and refreshments on each training day

Course dates
On-site course

In-company courses may be organised at any time and are extremely cost-effective on a ‘cost-per-student’ basis. The host company is responsible for the venue costs.

We can accommodate up to 10 (maximum) delegates per session.

Details/quote

Participants are typically Team Leaders, Continuous Improvement Champions and SC21 Change Agents. Some organization prefer to choose a group of 4 – 10 participants and have the courses delivered on site.

Every participant elects to undertake a major 'break-through' project which they work on over 3- to 6-month period. Consequently their newly acquired project management and continual improvement skills can be put to work immediately to the benefit of their organization.

TEC Transnational have chosen Minitab-18 as the preferred applications software for their Six Sigma Training Programme.

Individual benefits & Qualifications

  • Manufacturing industries are continually searching for ‘real problem solvers’ which provides an opportunity for individuals to gain the credentials of a Six Sigma ‘practitioner’
  • The skills you will learn enable you to become more proficient at managing ‘break-through’ projects that deliver tangible gains on the bottom line
  • Development of your leadership skills and added-value to your CV and LinkedIn profile

Individuals who attend all of the tutor-led training sessions and complete all of the course exercises and 'homework' will receive a Green Belt qualification

Individuals, who in addition, complete and submit an acceptable break through project will be awarded a Six Sigma Black Belt qualification

Organization benefits

  • Six Sigma enables organizations to improve their processes, making them more capable of delivering what the customer wants right-first-time, on-time and at cost. Combining the principles and practices of Lean Manufacturing serves to boost the ‘break-through’ improvements, and ensure that best practices are fully integrated. The resulting benefits to the organization can be substantial, and organizations will achieve –
    • greater productivity
    • higher throughput with the same resources
    • improved quality
    • reduced cycle times
    • less ‘fire fighting’
    • smoother operation – less hassle
    • reduced operating costs

TEC Transnational’s 'Master Trainers' have extensive experience deploying both Lean Manufacturing and Six Sigma in the aviation, defence, automotive, motorsport and rail sectors. We work with individual companies and supply chain groups.

Larger teams might benefit from our in-house courses. Fill out the form below and we will contact you with further details.

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