## Statistical Process Control (SPC exercise)

Statistical Process Control is a very significant exercise in Lean Six Sigma. It helps in analysing the process behaviour to identify the stability & capability of the processes. SPC determines critical control points in a process which impacts the quality of a product. Statistical Control Charts can obtain signals about when the process needs attention and when the process is best left alone.

## Statistical process control

Statistical process control |
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Introduction to SPC |

Purpose & Terminology |

Overview of process variation through simulation |

Understanding Normal distribution and variation |

Types of Data |

Control charts – Continuous data charts & variable data charts including CUSUM &EWMA exercises |

Introduction to Minitab 17 Software |

Control chart exerises using Minitab 17 software |

Process capabilty analysis- Cp,Cpk,Pp,Ppk |

Process capabilty analysis exercise using Minitab |

## Measurement System Analysis (MSA Simulation)

MSA is a technique to find out the credibility of the data used for analysis. This tools helps to identify measurement variation during the data collection process. MSA simulation course enables to understand the calculation methodologies, measurement errors. In this course, one can learn the basics of measurements, quantifying variation, errors, sources of errors and eliminate them.

## Measurement System Analysis

Measurement System Analysis |
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Introduction to MSA |

Purpose & Terminology |

Statistical properties of Measurement systems |

Understanding Normal distribution and variation |

Types of Data |

Overview of control charts. Average & Range charts, Capabilty analysis |

Measurement Equipment analysis. Bias, Accuracy, Linearity & Stabilty |

Introduction to Minitab Software |

Gage R&R. (Averge & Range method) Anova method |

Operational Definition, Data Collection Plan |

Attribute Agreement Analysis. |

## Lean Workshop

Lean workshop is meant for individuals keen on understanding and implementing Lean principles which deals with identifying and eliminating waste processes and improving process efficiency by doing only what is required at the right time. Unnecessary tasks, labor, inventory and costs are avoided using these principles.

## Lean Master Tool Kit

Lean Master Tool Kit | |
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Lean History/ Lean Motive: Order to Cash Cycle | |

Lean Basic Principles | |

A3 Report | |

Value Series | Taichi Ohno Circle |

Genchi Genbutsu | |

Muri – Mura – Muda | |

Current and Future State VSM | |

Value Waste Analysis | |

Value Stream Mapping | Value added activities |

Value Enabling | |

Standardization | |

Standard Sequence, Standard WIP | |

Takt Time | |

Time Analysis | Time Trap Analysis / Constraint Analysis |

Little’s Law – Lead Time Calculations | |

Process Cycle Efficiency | |

Cellular Manufacturing | |

Control | Jidoka, Poka Yoke |

Levels, Outcomes | |

Flow Management | Line Balancing |

Inventory Management | |

Visual Management and Work Place Organization | |

Super Market Pull, FIFO Pull | |

Pull | Khanban, Khanban card calculation |

Heijunka – Level Pull | |

SMED | |

Perfection | Just In Time – System Integration |

Kaizen – Process and Flow |

## Managerial Statistics for Decision making

Decision making in any organization is done based on thorough statistical analysis. This requires individuals involved in decision making to have a strong base on concepts such as probability, statistics, estimation, hypothesis, sampling distributions, regression and so on.

## MS Modules

MS Modules | |
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Stem and Leaf Display | |

Histogram and Frequency Polygon for Variables | |

Basic Statistical Concepts | Measures of Central Tendency |

Coefficient of Variation | |

Box Plot | |

Probability Distributions | |

Null and Alternative Hypothesis | |

Steps in Hypothesis Testing | |

Tests for Population Mean | |

Hypothesis Testing | Hypothesis Testing for the Equality of Two Means |

Hypothesis Testing for the Equality of Two Variables | |

Hypothesis Testing for the Equality of Two Proportions | |

Chi Square (x2) Tests of Hypothesis | |

Multi collinearty | |

Matrix Plot | |

Correlation-Regression Analysis | Linear Regression and Multiple Regression |

Logistic Regression | |

Logistic Regression | |

One-way Analysis of Variance | |

Analysis of Variance | Two-way Analysis of Variance |

Two-way Analysis of Variance | |

Software Applications | |

Decision Theory |

## Design of experiments

In order to identify factors and variables that can significantly impact the quality of the process, a scientific method should be adopted while designing an experiment for the same. When a strategically planned experiment with closely monitored variables is conducted, one can generate lot of information that is required for optimizing the process for improving process efficiency. This is possible through design of experiments (DOE)

## DOE Modules

Design of Experiments (DOE) | |
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History of DoE | |

Data Collection, Operational Definition | |

Pre DoE | Repeatability and Reproducibility Study |

Hypothesis Testing Fundamentals | |

Basic Hypothesis Test Experiments and Regression Model | |

Key Terminologies of DoE, Screening, Refining and Optimizing Designs | |

Steps to Conduct an Experiment, Full Factorial and Fractional Factorial Experiments | |

DoE | Analyze Output and Graphs: Factorial Design, Factorial Plots and Interaction Plots |

Response Surface Designs & Response Optimizer | |

Taguchi Desgins Overview |

## Failure mode & effect analysis

Failure mode & effect analysis (FMEA) enables the team to identify possible failures in the existing process or a new one. The cause, impact and resolution for the failure can then be evaluated and corrected. FMEA involves following certain methods, procedures, documentation and software which enables failure detection and analysis.

## FMEA

FMEA | |
---|---|

FMEA Process Overview | Introduction and course objectives |

The History and purpose of FMEA | |

FMEA in product development process | |

System/ subsystem/ component FMEA | |

FMEA Methodology | FMEA development methodology- The three path model |

Team structure and rules for efficiency | |

FMEA Linkage and Collaboration | The link between Design and Process FMEA |

What is Risk | |

RPN | |

Failure Mode Avoidance | |

Practical application of the Design FMEA technique | Interface analysis/ Boundary Diagram |

Parameter Diagram | |

DFMEA closure | Design review integration |

Test plan development | |

Failure Mode Avoidance |

## 7 QC tools

7 QC tools or 7 Quality Check Tools have been in use since a few decades. Propagated by a Japanese professor, Kaoru Ishikawa, these tools are as follows:

- Cause-and-effect diagram (also called Ishikawa or fishbone chart)
- Check Sheet
- Control charts
- Histogram
- Pareto chart
- Scatter diagram
- Stratification

## 7 QC

7 QC | |
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Procedures for Problem solving | Making use of data to increase productivity |

Applying the 7 QC tools towards problem solving | |

Plotting Pareto Diagrams | |

The Pareto Diagram | Classify the defects and display using Pareto Diagram |

Identify the problems in their order of severity | |

Plotting Fishbone Diagram | |

Fishbone Diagram (Cause & Effect Diagram) | Geberating probable causes for every defect |

Brainstorm technique | |

Process Flow Chart | Ploting Process Flow Chart |

Interpretation of PFC | |

Design review integration | |

Method to note data | Prevention of inspect slip-throughs |

Plotting checksheet for convenient usage | |

Predict occurence of defects | |

Histogram | Plotting Histogram |

Interpretation of shapes in a distribution diagram | |

Scatter Diagram | Plotting Scatter Diagram |

Interpretation of Scatter Diagram | |

Control Charts | Occurence of Defects |

Interpretation of a process with control charts |

## 5S

5S is a work place organization regime that ensures efficiency of process, labor, decision making by following the 5 principles – Sort (Seiri), Set In Order (Seiton), Shine(Seiso), Standardize (Seiketsu), Sustain (Shitsuke). Each of these help maintain and improvise a process and its corresponding workspace.

## 5S

5S | |
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What is 5s? | |

Origin of 5s | Where it came from? |

Benefits | |

Clearing the work area | |

The 5s methodology unpacked Sort (Seiri) | Determine what you need |

Set in Order (Seiso) | Designated locations |

Design your workplace for efficiency | |

Spic and span | |

Shine (Seiton) | Creating cleaning routines |

Making it routine | |

Standardize (Seiketsu) | Design systems to ensure new norms |

The benefits of 5S | |

Changing the future | |

Sustain (Shitsuke) | Techniques to prevent old habits |

The benefits of 5S | |

Zones & Zone members | |

Red tagging activity | |

Implemetation of 5S | challenges faced during deployment |

Tips for effective 5S |