Table of Contents

Workshop Introduction
Workshop Objectives ...................................................................... 2
Belt Certification Policy 101............................................................. 3
Learning Map .................................................................................. 5
Lean Six Sigma Tools ..................................................................... 9

What are Lean and Six Sigma?

Learning Objectives ........................................................................ 2
Quality ............................................................................................. 4
How to Think About Lean Six Sigma ............................................... 6
Where Is COPQ Found? ................................................................. 8
Total Quality Cost ............................................................................ 9
Understanding Variation ................................................................ 13
Six Sigma Level of Performance ................................................... 15
Lean Six Sigma Basic Premise ..................................................... 20
DMAIC........................................................................................... 23
DMADV ......................................................................................... 24
Lean VSM ..................................................................................... 26
Operational Definition: Value......................................................... 28
Why Define a Process as a Value Stream? .................................. 30
How to Identify the Eight Wastes .................................................. 32
Understanding Flow ...................................................................... 33
The VSM Roadmap ....................................................................... 37
Performance Improvement System ............................................... 40

Selection of Projects
Project Selection Method ................................................................ 2
Six Major Elements of a Project Charter ......................................... 3
Problem Statement ......................................................................... 6
Goal Statement ............................................................................... 8
Business Case and Expected Benefits ......................................... 13
Project Scope ................................................................................ 14
Project Plan Milestones ................................................................. 15

All Rights Reserved, Juran Institute, Inc. i 6507 SSGB.0910 V4

 Table of Contents
Team Membership and Resources ............................................... 16
Categorize by Method and Create Project Charter ....................... 18
Select Team .................................................................................. 20

Define
Learning Objectives ........................................................................ 2
Define the Y
Steps to Defining Customer CTQs .................................................. 5
Affinity Process ............................................................................... 7
Translation Steps .......................................................................... 11
Juran’s Pareto Analysis
Learning Objectives ...................................................................... 16
Concept ......................................................................................... 17
Pareto Diagrams ........................................................................... 20
Potential Pitfalls and Problems...................................................... 21
When to Use ................................................................................. 22
How to Construct a Pareto Diagram .............................................. 23
Define Current “As Is” Process
Definition of a Process .................................................................. 31
SIPOC ........................................................................................... 32
Create a SIPOC ............................................................................ 33
Benefits of Process Mapping......................................................... 34
Define Checkpoints for Completion .......................................... 36

Measure
Learning Objectives ........................................................................ 2
Definition of a Measure ................................................................... 3
Two Types of Measures .................................................................. 4
Sources of Variation: Common & Special ....................................... 7
Two Types of Data .......................................................................... 8
Central Tendency and Distribution ................................................ 11

All Rights Reserved, Juran Institute, Inc. ii 6507 SSGB.0910 V4

 Table of Contents
Data Collection
Learning Objectives ........................................................................ 2
Planning for Data Collection ............................................................ 3
Step 1: Establish Data-Collection Objectives .................................. 4
Step 2: Decide What to Measure .................................................... 5
Step 3: Decide How to Measure...................................................... 8
Steps 4 and 5 .................................................................................. 9
Steps 6 and 7 ................................................................................ 10

Detailed Process Map

Learning Objectives ........................................................................ 2
Concept ........................................................................................... 3
Steps to Detailed Mapping .............................................................. 8
Identify Moments of Truth................................................................ 9
How to Interpret Process Maps ..................................................... 10
Potential Problems in Interpretation .............................................. 12

Displaying Data
Learning Objectives ........................................................................ 2
Concept ........................................................................................... 3
Line Graph ...................................................................................... 4
Bar Graph........................................................................................ 5
Stacked Bar Graph .......................................................................... 6
Pie Chart ......................................................................................... 7
How to Interpret Graphs and Charts ............................................... 8
What Chart Do I Use? ................................................................... 10
Histograms
Learning Objectives ...................................................................... 12
Concept ......................................................................................... 13
How to Construct........................................................................... 15
Histogram Interpretation ................................................................ 22
Patterns of Distribution .................................................................. 23

All Rights Reserved, Juran Institute, Inc. iii 6507 SSGB.0910 V4

 Table of Contents
Stratifying Data With Box Plots
Learning Objectives ...................................................................... 32
Concept ......................................................................................... 33
How to Construct a Box Plot ......................................................... 38
How to Interpret Box Plots............................................................. 43

Sampling
Learning Objectives ........................................................................ 2
Concept ........................................................................................... 3
Intro to Sample Size ........................................................................ 4
Population or Sample ...................................................................... 5
Qualities of a Good Sample ............................................................ 7
Random Sampling ........................................................................... 9
Sampling Bias ............................................................................... 11
Sampling Confidence Intervals ...................................................... 12
Typical Sample Size ...................................................................... 14

Standard Normal Distribution

Learning Objectives ........................................................................ 2
Understanding Probability ............................................................... 3
Normal Probability Curve ................................................................ 7
The Normal Distribution .................................................................. 8
Calculate Z Value ............................................................................ 9
Standard Deviation ........................................................................ 11
Central Limit Theorem ................................................................... 14

Measurement System Analysis

Learning Objectives ........................................................................ 2
The Fundamental MSA Question .................................................... 5
Bias ................................................................................................. 6
Repeatability ................................................................................... 7
Reproducibility................................................................................. 8
How to Complete MSA Studies ....................................................... 9
Attribute MSA Method ................................................................... 13

All Rights Reserved, Juran Institute, Inc. iv 6507 SSGB.0910 V4

 Table of Contents
Measurement System Analysis-Continuous Data
Learning Objectives ...................................................................... 23
Possible Sources of Variation ....................................................... 27
Calibration or Gage R&R Study? .................................................. 28
Interpretation of Measurement ...................................................... 29
Gage Bias Defined ........................................................................ 31
Gage Reproducibility Defined........................................................ 32
Gage Repeatability Defined .......................................................... 33
Acceptance Criteria ....................................................................... 35

Calculating Sigma Level

Learning Objectives ........................................................................ 2
Sigma Level and Standard Deviation .............................................. 3
DPU and DPO ................................................................................. 5
Abridged Process Sigma Conversion Table .................................... 7
Calculating Sigma Level – Yield ...................................................... 9
When Do You Perform a Process Capability Study? .................... 16
Prediction of Defect Levels............................................................ 18
Capability Indices (Long-term vs. Short-term) ............................... 22

Identify Potential Xs
Learning Objectives ........................................................................ 2
Project Xs ........................................................................................ 3
Brainstorming .................................................................................. 7
Cause-Effect Diagrams
Learning Objectives ...................................................................... 10
Concept ......................................................................................... 11
How to Construct Cause-Effect Diagrams ..................................... 16
How to Interpret............................................................................. 18
Failure Mode Effect Analysis
Learning Objectives ...................................................................... 24
How Does an FMEA Work? .......................................................... 26
How to Construct........................................................................... 29
When Is an FMEA Complete? ....................................................... 34

All Rights Reserved, Juran Institute, Inc. v 6507 SSGB.0910 V4

 Table of Contents
Measure Checkpoints for Completion ....................................... 37

Analyze
Learning Objectives ........................................................................ 2
Types of Analysis ............................................................................ 3
Planning the Tests .......................................................................... 4

Stratification
Learning Objectives ........................................................................ 2
What is Stratification? ..................................................................... 3
How to Stratify ................................................................................. 8

Hypothesis Testing Introduction

Learning Objectives ........................................................................ 2
Alpha and Beta Risk ........................................................................ 5
Formulating the ―Null‖ & ―Alternative‖ Hypotheses .......................... 9
Hypothesis Testing Definitions ...................................................... 10
Hypothesis Testing: P-Value ......................................................... 11
Steps in Hypothesis Testing ......................................................... 12

Confidence Intervals
Learning Objectives ........................................................................ 2
Definition of the Confidence Interval ............................................... 4
The Confidence Interval Equation ................................................... 6
What Is the t Distribution? ............................................................... 8

Y Is Categorical & X Is Categorical

Learning Objectives ........................................................................ 2
Contingency Table Description ..................................................... 13
Chi-Square Test for Independence ............................................... 14

Normality Tests
Learning Objectives ........................................................................ 2
Normality Test Method .................................................................... 3
Test for Equal Variance
Learning Objectives ...................................................................... 10

All Rights Reserved, Juran Institute, Inc. vi 6507 SSGB.0910 V4

 Table of Contents
Comparing Two Variances ............................................................ 11

Y Is Continuous & X Is Categorical

Learning Objectives ........................................................................ 2
1-Sample t-Test............................................................................... 3
2-Sample t-Test............................................................................. 11

ANOVA
Learning Objectives ........................................................................ 2
ANOVA Method ............................................................................... 4
What Are Fits and Residuals ......................................................... 11

Nonparametric Tests
Learning Objectives ........................................................................ 2
Definition of Nonparametric ............................................................. 4
Wilcoxon.......................................................................................... 8
Mann-Whitney ............................................................................... 12
Kruskal-Wallis ............................................................................... 21

Y Is Continuous & X Is Continuous

Learning Objectives ........................................................................ 2
Scatter Diagram .............................................................................. 3
Typical Patterns of Correlation ........................................................ 8
Correlation and Regression Topics ............................................... 23
Correlation Relationship Significance Table .................................. 27
Correlation Data Requirements ..................................................... 28
Regression .................................................................................... 31
Linear Relationship ....................................................................... 32
Analyze Checkpoints for Completion ........................................ 39

Improve
Learning Objectives ........................................................................ 2
Step 1: Generate Solutions ............................................................. 4

All Rights Reserved, Juran Institute, Inc. vii 6507 SSGB.0910 V4

 Table of Contents
Sources of Solutions ....................................................................... 5
Tool: Benchmarking ........................................................................ 7
Tool: Detailed Process Map ............................................................ 8
Step 2: Evaluate Possible Solutions.............................................. 12
Tool: Selection Matrix .................................................................... 16
Tool: Pugh Matrix .......................................................................... 17
Tool: Payoff Matrix ........................................................................ 20
Step 3: Design Solution, Controls, for Culture ............................... 21
Design the Solution—Change ....................................................... 22
Rules of the Road ......................................................................... 25
Tool: Barriers and Aids chart ......................................................... 28
Assess Risk: Pros and Cons ......................................................... 32

Introduction to DOE
Learning Objectives ........................................................................ 2
Design of Experiment Overview ...................................................... 3
Improvement Approaches ............................................................... 5
DOE Terminology ............................................................................ 9
Types of Designed Experiments ................................................... 11
DOE Steps – Prepare ................................................................... 15
DOE Steps – Perform ................................................................... 17
DOE Steps – Analyze ................................................................... 19
DOE Steps – Conclude ................................................................. 27

Prove Effectiveness
Step 4: Prove Effectiveness ............................................................ 2
Pilot Test Defined ............................................................................ 4
Step 5: Develop Implementation Plan ............................................. 9
Improve Checkpoints for Completion ....................................... 11

Control
Learning Objectives ........................................................................ 2
Identify Control Subjects ................................................................. 4
The Feedback Loop ...................................................................... 14

All Rights Reserved, Juran Institute, Inc. viii 6507 SSGB.0910 V4

 Table of Contents
Regulating a Process .................................................................... 15
Self-Control Checklist .................................................................... 18
Significance of Self-Control ........................................................... 20
Management-Controllable Errors .................................................. 21
Employee-Controllable Errors ....................................................... 22

Mistake Proofing
Learning Objectives ........................................................................ 2
Mistake Proofing ............................................................................. 3
Defects vs. Errors ............................................................................ 7
Levels of Mistake Proofing ............................................................ 10
Process Control Plan
Learning Objectives ...................................................................... 13
Concept ......................................................................................... 14
Process Control Plan Contents ..................................................... 16
When to Use ................................................................................. 18
How to Construct........................................................................... 19

SPC Methods
Learning Objectives ........................................................................ 2
Concept ........................................................................................... 3
Goal of a Process Control System .................................................. 6
Sources of Variation ........................................................................ 7
Control Charts and SPC .................................................................. 8
Control Limits vs. Specification Limits ............................................. 9
Definitions ..................................................................................... 11
Selection of Control Charts ........................................................... 16
Control Charts: Steps to Construct and Analyze ........................... 18
Shewhart Control Chart Model ...................................................... 20
Out of Control (OOC) Condition .................................................... 23
P Chart .......................................................................................... 34
C Chart .......................................................................................... 42

Document and Replicate

All Rights Reserved, Juran Institute, Inc. ix 6507 SSGB.0910 V4

 Table of Contents
Project Documentation .................................................................... 3
Project Closure Checklist ................................................................ 7
Control Checkpoints for Completion................................................ 9

Glossary

All Rights Reserved, Juran Institute, Inc. x 6507 SSGB.0910 V4