P R O C E S S I M P R O V E M E N T AIMING FOR WORLD CLASS PERFORMANCE P R O C E S S I M P R O V E M E N T ENSCHEDE Institutenweg 26 7521 PK Enschede The Netherlands T +31 (0)53-2030240 F +31 (0)53-2030241 info@symbolbv.nl www.symbolbv.nl UTRECHT Graadt van Roggenweg 328 3531 AH Utrecht The Netherlands T +31 (0)30-7118853 3 COMPANIES AND ORGANISATIONS MUST CONSTANTLY WORK TO IMPROVE THEIR KNOWLEDGE OF QUALITY CONTROL TO RESPOND TO THE INCREASING REQUIREMENTS for shorter lead times and higher quality. Well-trained employees THEREFORE PLAY AN IMPORTANT ROLE IN THE OPERATION AND OUTCOMES OF THE ORGANISATION. FORWORD Forword to achieve change, knowledge and expertse are needed. symbol organises training and educaton in process improvement at all levels with a constant focus on the practcal applicability of theoretcal tools. Symbol is a leading service provider and trainer in process improvement and assists companies and organisatons improve quality and shorten lead tmes. experienced Black Belts and Master Black Belts train employees in Lean and Six Sigma methods and tools, and then coach them in executng their projects. symbol Black Belts and master Black Belts have extensive experience in a wide variety of felds including industry, product development, service, public sector, constructon, and transactonal processes. We are happy to help you improve your processes and operatonal results. the training courses in this guide are your frst step towards improved processes and operatonal excellence. Dick Theisens General Manager, Symbol BV 4 Introducton Management & Quality Public Sector & Administraton Industry & Food INTRODUCTION 6 MANAGEMENT & QUALITY 8 Lean Six Sigma Champion 9 internal & external auditng 10 PUBLIC SECTOR & ADMINISTRATION 11 Lean Six Sigma Orange Belt 12 Lean Six Sigma Green Belt 13 Lean Six Sigma Black Belt 14 INDUSTRY & FOOD 15 Lean Basics 16 tpm - total productve maintenance 17 VSM - Value Stream Mapping 18 spC - statstcal process Control 19 8D - Problem Solving 20 Lean Six Sigma Yellow Belt (E-learning) 21 Lean Six Sigma Orange Belt 22 Lean Six Sigma Green Belt 23 Lean Six Sigma Black Belt 24 Contents 5 Product Development Certfcaton Terms & Conditons PRODUCT DEVELOPMENT 25 fmea - failure mode efect analysis 26 DOE - Design of Experiments 27 DfSS - Design for Six Sigma 28 CERTIFICATION 29 LSSA - Lean Six Sigma Academy 30 yellow / orange Belt Certfcering 31 green / Black Belt Certfcering 32 TERMS & CONDITIONS 33 Contents 6 Introduction INTRODUCTION 7 Open Training & In-company open training courses are organised at various locatons which can be found on our website. All training courses in this guide are also available in-company. Three basic packages have been compiled for Lean Six Sigma training. Tailor made programs are also available. Our training advisor is happy to help you determine a customised training program that best suits your needs. LSSA Lean Six Sigma Academy Lean Six Sigma training programs are based on the European LSSA skill sets. these skill sets provide a detailed descripton of learning elements that partcipants will have acquired afer completng the training program. the level upon which these learning elements may be applied is also described. The LSSA skill sets can be downloaded from www.symbolbv.com or www.LSSA.eu. Teaching Styles a variety of teaching styles are used during training. in additon to theory, much tme is also spent working on exercises and case studies both individually and in groups. Within some training programs, homework is also given. For many elements, games are used to guide partcipants using an informal method of learning by doing. Within the training, there is much room for discussion and for partcipants to share experiences with one another. partcipants following Lean Six Sigma training programs achieve the best results when working on their projects within their own organisaton in parallel to their training. Certfed Training all partcipants receive a certfcate of partcipaton. it is also possible to obtain an ofcial european certfcate for lean six sigma training. this is organised through a partnership between the ECQA, LSSA and the University of Twente. more informaton can be found in the back of this guide. Customer Satsfacton the feld of process improvement is about quality and efectveness. Customer satsfacton is therefore of utmost importance to us. We are contnuously evaluatng and improving our training programs. symbol has received much appreciaton from its customers Workshops and Company Visits We regularly organise short workshops within which diferent methodologies and tools are introduced. We also organise company visits, which allow partcipants to see companies that have successfully implemented lean and/or six sigma. partcipaton in most of these actvites is free. you can fnd more informaton and enrol directly on our website. 8
Management & quality MANAGEMENT & QUALITY 9
LEAN SIX SIGMA CHAMPIONS ARE PRINCIPAL LEAN SIX SIGMA PROJECT INITIATORS. CHAMPIONS IDENTIFY PROJECTS THAT CONTRIBUTE TO DEPARTMENTAL AND BUSINESS GOALS, AND COACH GREEN AND BLACK BELTS IN LEAN SIX SIGMA IMPLEMENTATION. Lean Six Sigma Champion MANAGEMENT & QUALITY managers, project managers and other executives from companies and organisations who are either actively engaged in lean six sigma or just started implementing Lean Six Sigma in the workplace. On completion of this training, you will be able to demonstrate how Lean Six sigma contributes to business objectives. you will also be able to properly select projects, and identify and assess project progress. finally, you will understand the success factors involved in Lean Six Sigma introduction. World Class performance (lean, six sigma, dfss, tpm and toC) implementing lean scan & lean roadmap dmaiC roadmap (sample project) project selection (select, prioritise and define) lean six sigma organisation (roles and responsibilities) lean principles (Value, Value stream, flow, pull, Continuous improvement) lean tools (5s, Jit, one piece flow, Vsm, ) establishing Kaizen organisation / Continuous improvements teams hoshin planning / policy deployment Cap Change acceleration process / deployment success factors asking the right questions during lean six sigma tollgate reviews In addition to theoretical knowledge, we also discuss the practical application of Lean Six Sigma within your company. Learning from each other is an important part of this training. Each participant is provided with a training manual including all presentations and exercises. Participants also receive a Lean Scan template. Management 1 to 2 days (depending on objectives) in-company price available upon request Target Group Objectve Content Material Level Duration Price Management & quality GOVERNMENT LOGISTICS INDUSTRY 10
AUDITORS TODAY ARE NOT ONLY INTERESTED IN ENSURING THAT THE RULES ARE BEING FOLLOWED. AUDITING IS ABOUT PROVIDING INSIGHT INTO RISKS AND IMPROVEMENT POSSIBILITIES FOR THE ORGANISATION. AUDITING INDICATES THE STATE OF YOUR ORGANISATION AND PROVIDES INSIGHT INTO PROCESS PERFORMANCE, ORGANISATIONAL PERFORMANCE AND IMPROVEMENT POSSIBILITIES. Internal & External Auditing production managers, quality managers, line managers, engineers and purchasers. During this training you will learn how to conduct audits within your own organisation and with suppliers. Because we also focus on tools such as Capability Analysis and FMEA, you will also learn how to look beyond the procedures described in the quality handbook. you will be able to better assess the interface interactions of various departments. Finally, on completion of this training you will be familiar with the 8D process which will help you control and handle complaints more effectively. We start with the most common standards and assessment practices. We focus on the audit preparation, the execution, the reporting and on the follow-up actions. The focus of the training is based on the modern way of auditing: the advisory and coaching role in the improvement process. standards (iso 9001, 14001, 18001 & ts-16949) the goal of auditing process audit vs. product audit the auditing process (preparation, execution, reporting and monitoring) auditing from standard methods monitoring performance and quality (Kpis yield, ppm, ) awareness of variation and introduction to process Capability handling complaints using the 8d process Case treatment Each participant is provided with a training manual including all presentations and exercises. From secondary vocational education to extensive experience as a professional 2 days in-company price available upon request Target Group Objectve Content Material Level Duration Price INDUSTRY 11 Public sector & administraton
PUBLIC SECTOR & ADMINISTRATION 12 LEAN SI PUBLIC SECTOR & ADMINISTRATION Public sector & administraton
LEAN SIX SIGMA ORANGE BELTS ARE KNOWLEDGEABLE IN THE FIELD OF BASIC PROBLEM SOLVING AND ARE FAMILIAR WITH LEAN SIX SIGMA METHODOLOGIES AND TOOLS. ORANGE BELTS ARE IMPROVEMENT PROJECT TEAM LEADERS WITHIN THEIR DIRECT WORK ENVIRONMENT AND PROVIDE CONSTRUCTIVE CONTRIBUTIONS TO LARGER LEAN SIX SIGMA GREEN/ BLACK BELT PROJECTS. Lean Six Sigma Orange Belt All employees directly or indirectly involved in process improvement programs including process owners, administrative and financial officers and quality staff. On completion of the Lean Six Sigma Orange Belt training, you will be familiar with Lean and Six Sigma methodologies as well as the most important tools, concepts and abbreviations within Lean Six Sigma. You will learn what Lean Manufacturing and Six Sigma can do for your service organisation and how you can contribute to process improvements. lean principles (Value, Value stream, flow, pull, Continuous improvement) Voice of the Customer & Ctq flowdown measuring process performance data Visualisation 5s Workplace organisation process Visualisation identifying and eliminating waste risk analysis with failure mode effect analysis analytical techniques(pareto, Cause & effect, Capability, ...) Variation identification and reduction Kaizen Continuous improvement at the office Each participant is provided with a training manual including all presentations and exercises. From secondary vocational education to higher education 4 days in-company price available upon request Target Group Objectve Content Material Level Duration Price GOVERNMENT LOGISTICS 13
LEAN SIX SIGMA GREEN BELTS IN SERVICE ORGANISATIONS AND PUBLIC SECTOR ARE RESPONSIBLE FOR ORGANISING AND IMPLEMENTING EFFICIENT PROCESSES. WITH THE RIGHT COMBINATION OF SPECIALISED EXPERTISE, LEAN MANAGEMENT, STATISTICAL ANALYSIS AND THE STRUCTURED LEAN SIX SIGMA METHODOLOGY, LEAN SIX SIGMA GREEN BELTS ARE CAPABLE OF ACHIEVING SIGNIFICANT QUALITY AND PERFORMANCE IMPROVEMENTS. Lean Six Sigma Green Belt Target Group Objectve Content Material Level Duration Price project leaders, department managers, process owners and process managers. After completing this training program, it is possible to move on to the Black Belt training program. On completion of this training, you will have a new outlook on processes. You will be able to identify unnecessary activities and objectively assess process performance. You will be an expert in the tools needed to efficiently design processes and reduce errors. The result is improved process performance and better product quality. this translates into lower costs and higher customer satisfaction. lean principles (Value, Value stream, flow, pull, Continuous improvement) project management (roles & responsibilities, project Charter, dmaiC, ..) Voice of the Customer & Ctq flowdown process performance metrics process measurement & measurement system analysis Visualisation of data with minitab (Pareto, Bar Chart, Pie Chart, Dot Plot, Histogram, Box Plot, Time Series Plot, Scatter Plot) analytical techniques (pareto, Cause & effect, Capability, ...) 5s workplace organisation process mapping & Value stream mapping identifying and eliminating waste risk analysis using failure mode effect analysis statistical techniques (Hypotheses, Correlation, Regression, ANOVA, SPC, Probability...) Kaizen Continuous improvement at the office lean simulation game, six sigma case & practice exam the detailed lssa skill set with all subjects and learning objectives can be downloaded from our website. Each participant is provided with two training manuals including presentations and exercises. Participants will also receive a variety of practical templates and the book Applying Lean Six Sigma in Service & Public sector by Quentin Brook. During the training we use Minitab. A 30-days trial version can be downloaded at www.minitab.com. Higher education / university level 8 days (within approximately 3 months) in-company price available upon request GOVERNMENT 14 LEAN SI PUBLIC SECTOR & ADMINISTRATION
LEAN SIX SIGMA BLACK BELTS IN SERVICE ORGANISATIONS AND PUBLIC SECTOR ARE BOTH PROCESS ANALYSTS, RESPONSIBLE FOR ANALYSING AND OPTIMISING PROCESSES AS WELL AS CHANGE MANAGERS, RESPONSIBLE FOR IMPLEMENTING AN EFFECTIVE ORGANISATION. THESE PROFESSIONALS ARE ABLE TO COMBINE ANALYTICAL TOOLS WITH ASPECTS OF CHANGE MANAGEMENT. Lean Six Sigma Black Belt project managers, department managers, business consultants and process owners. On completion of this training, you will have developed an extensive set of tools to analyse processes. you will be able to objectively assess process performance and use statistics to support your findings. You will also learn how organisations can design more efficient and effective processes. This translates into lower operating costs, higher customer satisfaction and an effective organisation. setting up a lean six sigma organisation project management (project Charter, dmaiC, ...) process performance metrics & measurement system analysis (msa) Visualising data using minitab (Pareto, Bar Chart, Pie Chart, Dot Plot, Histogram, Box Plot, Time Series Plot, Scatter Plot) organising the workplace environment and activities (5s) process mapping & Value stream mapping identifying and eliminating waste instruments for analysing problems & Brainstorming set-up and implementation of experiments using design of experiments (DOE, RSM, ..) statistical analysis (probability distribution, non-normal data, Transformations, SPC+,...) analysing attribute data (Chi-square, attributive agreement, ..) theory of Constraints (toC) lean accounting human dynamics & Change acceleration process (Cap) lean simulation game, six sigma cases & practice exam the detailed lssa skill set with all subjects and learning objectives can be downloaded from our website. Each participant is provided with three training manuals including presentations and exercises. Participants will also receive a variety of practical templates and the book Applying Lean Six Sigma in Service & Public sector by Quentin Brook. During the training we use Minitab. A 30-days trial version can be downloaded at www.minitab.com Higher education / university level (with basic statistical knowledge) 14 days (within approximately 3 to 4 months) in-company price available upon request Target Group Objectve Content Material Level Duration Price GOVERNMENT 15 Industry & Food INDUSTRY & FOOD 16 LEAN SI INDUSTRY & FOOD Industry & Food
DURING THE LEAN GAME, THE GROUP HAS THE GOAL TO ASSEMBLE AS MANY PRODUCTS AS POSSIBLE WITHIN A SPECIFIED TIME. IN THE FIRST ROUND, THERE IS NO COLLABORATION OR PREPARATION WHICH RESULTS IN A CHAOTIC PROCESS AND A DISAPPOINTING RESULT. AFTER A NUMBER OF ROUNDS, IT QUICKLY BECOMES CLEAR THAT ALTERNATIVES ARE AVAILABLE. Lean Basics Any employee directly or indirectly involved in a Lean process. Lean games give employees insight into themselves by allowing them to experience the results that are possible if they use the Lean principles. On completion of this game, participants have their eyes opened to the benefits of Lean and everyone is able to identify what this means for their own work and for the work environment. Lean games are also excellent for teambuilding. There are two different Lean games available for different types of organisations: aircraft simulation game for project-based organisations and batch processes order processing game for administrative organizations and service providers We start by explaining the Lean principles (Value, Value Stream, Flow, Pull and Continuous Improvement) and the 8 types of Waste. We play three rounds, with theory and guidance provided in between. The first round will not lead to the preferred results. The so called rush order will undoubtedly be delivered too late. Participants are then faced with work-in-progress and with the quality problems that will most certainly arise After receiving a few tips, the team has the time to analyse their own processes and methods. This boils down to no mistakes, good teamwork and communication, balancing of work activities, One-Piece-Flow, Pull and controlling work-in-progress. Good preparation and teamwork eventually lead to an amazing result! Each participant is provided with a training manual including all presentations. All levels / all departments 1 day in-company price available upon request Target Group Objectve Content Material Level Duration Price LOGISTICS INDUSTRY CONSTRUCTION 17
TPM STANDS FOR TOTAL PRODUCTIVE MAINTENANCE AND IS A STRATEGY USED TO IMPROVE THE EFFECTIVENESS OF THE AVAILABLE PRODUCTION RESOURCES AND TO REDUCE MACHINE RELATED REJECTION. TPM IS MAINLY USED IN PRODUCTION ENVIRONMENTS THAT ARE HIGHLY MACHINE DEPENDANT. TPM - Total Productive Maintenance All employees directly or indirectly involved in increasing machine efficiency, adjusting machines, and reducing machine related downtime. On completion of this practical training, you will be familiar with the TPM methodology and you will understand the similarities and differences between different process improvement methods. You will be able to prepare measurement systems to measure machine effectiveness (oee overall equipment effectiveness). in addition we cover a number of practical methodologies and tools that focus on increasing the effectiveness of your machine park. similarities and differences: tpm and lean the tpm strategy and the tpm pillars Calculating efficiency, effectiveness and productivity. Various calculations for line failures (yield) production effectiveness quantification Calculating ratios for availability, performance and quality preparation of oee measurement methods in excel including use of the oeetoolkit graphical presentation of oee performance preparation and implementation of an improvement plan 5s workplace organisation Kaizen continuous improvement (pdCa) guidelines for tooling design smed: method to reduce changeover times Each participant is provided with a training manual including all presentations. Secondary vocational education 2 days in-company price available upon request Target Group Objectve Content Material Level Duration Price INDUSTRY 18 LEAN SI
VALUE STREAM MAPPING IS ONE OF THE MOST POWERFUL LEAN INSTRUMENTS. IT HELPS MAP OUT PROCESSES AND MAKE THEM MORE EFFICIENT. THE GOAL IS TO SHORTEN TURNAROUND TIME AND REDUCE INVENTORY LEVELS. THE STARTING POINT IS ALWAYS CLIENT AND CUSTOMER VALUE. VSM - Value Stream Mapping TPM - Total Productive Maintenance Managers, business leaders, supervisors, logistics, (process) engineers and process owners. On completion of this training you will be able to clearly identify your customer and what Value really means for this customer. You will be able to apply various instruments to map your processes. In addition, you will be able to define the value stream and calculate both lead times and inventory turnover. You will be able to differentiate between value-adding activities and non-value adding activities and identify waste. You will also be able to design a Future State to help you realise a more efficient process. lean principles (Value, Value stream, flow, pull and Continuous improvement) toyota production system identifying the 8 types of waste experience lean (lean game) process flow mapping, sipoC and swim lanes Value stream mapping Current state Value stream mapping future state Calculations: lead time and inventory turnaround time Controlling work in progress, ConWip heijunka balancing Various Kanban systems Kaizen continuous improvement Each participant is provided with a training manual including all presentations Secondary vocational education 2 days in-company price available upon request Target Group Objectve Content Material Level Duration Price INDUSTRY & FOOD GOVERNMENT LOGISTICS INDUSTRY CONSTRUCTION 19
SPC INVOLVES THE USE OF STATISTICAL TECHNIQUES TO MEASURE AND ANALYSE VARIATION IN A PROCESS. THE GOAL OF SPC IS TO MEASURE THE STABILITY AND CAPABILITY OF A PROCESS IN A CLEAR AND SIMPLE WAY. THIS ALLOWS ONE TO MAKE THE MOST APPROPRIATE ARRANGEMENTS TO IMPROVE AND MANAGE THE PROCESS. SPC HELPS YOU LISTEN TO THE VOICE OF THE PROCESS. SPC - Statistical Process Control design engineers, process engineers, quality engineers, line supervisors and machine operators. On completion of this training you will be able to design the most employed control charts, to interpret the results of control charts and to decide whether a process is In-control or Out-of-control. In addition to theoretical explanations, we make use of SPC software. An interactive exercise involving a catapult helps participants collect data. The data is then input into a self-designed Control chart. Participants analyse the data and then determine whether or not the catapult process is In-control. history and philosophy of spC data types and data collection important distributions (normal, poisson, Binominal) Common cause vs. special cause variation process capability vs. process performance specification limits vs. Control limits using definitions and symbols using common control charts for Variable data (individualX; imrChart and Xbarr Chart) and attributive data (npChart; pChart; cChart; uChart) Control chart interpretation out-of-Control rules the role of Control Charts in improvements programs the implementation of spC in the organisation and the transfer of SPC to the work floor During the training we provide a training manual including all the presentations and exercises. During the training we use Minitab. A 30-days trial version can be downloaded at www.minitab.com. Secondary vocational education 2 days in-company price available upon request Target Group Objectve Content Material Level Duration Price INDUSTRY 20 LEAN SI
the 8d proBlem solVing proCess is a standardised plan (originally deVeloped By ford) that uses eight steps to address a proBlem. 8d is also an important COMMUNICATION TOOL AND A THEMATIC APPROACH USED IN PROJECTS. WITHIN THE AUTOMOTIVE INDUSTRY, AN 8D IS THE STANDARD APPROACH EMPLOYED IF THERE ARE PROBLEMS WITH DELIVERED PRODUCTS. OTHER SECTORS ARE ALSO USING 8D MORE AND MORE TO EFFECTIVELY SOLVE PROBLEMS AND GUIDE COMMUNICATION. 8D - Problem Solving SPC - Statistical Process Control Anyone directly or indirectly involved in problem solving and interested in employing a structured approach to do so. Departments such as product development, production and quality would find this training valuable. On completion of this training you will be able to define and analyse problems in a structured way. You will also learn how to look for abnormalities and for the cause of a problem. You will receive a number of tools that can be used to find the cause of a problem and will learn to apply these tools during the course. 8d methodology and roadmap rCa root Cause analysis preparing the problem definition defining projects (scope) quantifying the problem (pareto, Check sheet, Bar chart, ) flow chart set up histogram, time series plot, Correlation Brainstorming 5Why methodology and isis not Cause & effect diagram / fishbone Cause & effect matrix The content is tailor-made to suit your organisation. Together with the trainer you determine the training content. The organisation also brings its own problems to the training session which are then treated during the training. Each participant is provided with a training manual including all presentations. During the training we use Excel. Secondary vocational education 2 days in-company price available upon request Target Group Objectve Content Material Level Duration Price INDUSTRY & FOOD INDUSTRY 21
LEAN SIX SIGMA YELLOW BELTS ARE FAMILIAR WITH LEAN MANUFACTURING PRINCIPLES AND THE SIX SIGMA APPROACH. YELLOW BELTS APPLY LEAN SIX SIGMA TOOLS IN THEIR IMMEDIATE WORK ENVIRONMENTS AND AS TEAM MEMBERS, YELLOW BELTS PROVIDE CONSTRUCTIVE CONTRIBUTIONS TO LARGER OPTIMISATION PROJECTS. THIS PROGRAM IS OFFERED ONLINE ALLOWING YOU TO FOLLOW THE TRAINING AT YOUR OWN PACE. YOU ARE CONNECTED WITH OTHER STUDENTS AND EXPERIENCED BLACK BELT TRAINERS VIA EMAIL AND SKYPE SESSIONS. Lean Six Sigma Yellow Belt (E-learning) All employees directly or indirectly involved in workplace improvement programs. On completion of the Lean Six Sigma Yellow Belt training programme, you will be familiar with Lean and Six Sigma methodologies. You will be able to effectively solve production problems and will be capable of offering significant contributions to larger projects as a respected team member. This training consists of 23 instruction videos and exercises that you can follow at your own pace. The training is available in English, Dutch and French. additionally, you have the opportunity to ask questions via email that are answered by an experienced Master Black Belt. introduction to lean six sigma lean principles roles & responsibilities project management VoC & Ctq flowdown process mapping data types Basic statistics data Visualisation measurement systems process performance metrics process Capability & performance regression analysis hypothesis testing failure mode & effect analysis root Cause analysis Value stream mapping 5s Workplace organisation Kaizen Continuous improvement lean simulation game statistical process Control Visual management quality assurance We provide 23 instructional videos, each video running approximately 15 minutes. The presentations, texts and exercises can be downloaded at the learning portal. All levels Approximately 10-15 hours of instruction time 495,- p.p. Target Group Objectve Content Material Level Duration Price LOGISTICS INDUSTRY 22 LEAN SI
LEAN SIX SIGMA ORANGE BELTS ARE KNOWLEDGEABLE IN THE FIELD OF BASIC PROBLEM SOLVING AND ARE FAMILIAR WITH LEAN SIX SIGMA METHODOLOGIES AND TOOLS. ORANGE BELTS ARE IMPROVEMENT PROJECT TEAM LEADERS WITHIN THEIR DIRECT WORK ENVIRONMENT AND PROVIDE CONSTRUCTIVE CONTRIBUTIONS TO LARGER LEAN SIX SIGMA GREEN/ BLACK BELT PROJECTS. Lean Six Sigma Orange Belt Lean Six Sigma Yellow Belt (E-learning) Operators, managers, supervisors and engineers directly or indirectly involved in process improvement programs. On completion of the Lean Six Sigma Orange Belt training, you will be familiar with Lean and Six Sigma methodologies as well as the most important tools, concepts and abbreviations within Lean Six Sigma. You will learn what Lean Manufacturing and Six Sigma can do for your company. You will also learn how to solve production problems in an effective manner. lean principles (Value, Value stream, flow, pull, Continuous improvement) lean simulation game & lean six sigma case (dmaiC) Voice of the Customer & Ctq flowdown measuring process performance (yield, dpmo, ppm, ..) spC statistical process Control msa measurement system analysis / gage r&r% fmea failure mode effect analysis 5s Workplace organisation Vsm Value stream mapping identifying and eliminating waste Visualising data / introduction to minitab (Pareto, Bar Chart, Pie Chart, Dot Plot, Histogram, Box Plot, Time Series Plot, Scatter Plot) problem solving tools (pareto, Cause & effect, Capability, ...) Basic statistics (Correlation, regression, probability, ...) Kaizen Continuous improvement / pdCa Each participant is provided with a training manual including all presentations and exercises. Secondary vocational education 4 days in-company price available upon request Target Group Objectve Content Material Level Duration Price INDUSTRY & FOOD INDUSTRY 23
LEAN SIX SIGMA GREEN BELT SPECIALISTS ARE RESPONSIBLE FOR PROCESS PLANNING AND PROCESS OPTIMISATION. WITH THE RIGHT COMBINATION OF SPECIALISED EXPERTISE, STATISTICAL ANALYSIS AND THE STRUCTURED LEAN SIX SIGMA METHODOLOGY, LEAN SIX SIGMA GREEN BELTS ARE CAPABLE OF ACHIEVING SIGNIFICANT QUALITY AND PERFORMANCE IMPROVEMENTS. Lean Six Sigma Green Belt design, process and quality engineers, project leaders and department managers. On completion of this training, participants are able to structurally and effectively analyse and solve production problems. The result is improved process performance and better product quality. this translates into lower costs and higher customer satisfaction.
lean principles (Value, Value stream, flow, pull, Continuous improvement) project management (roles & responsibilities, project Charter, dmaiC, ..) Voice of the Customer & Ctq flowdown process performance metrics process flow mapping & sipoC problem solving (8d, Cause & effect, 5Why, ..) Visualisation of data with minitab (Pareto, Bar Chart, Pie Chart, Dot Plot, Histogram, Box Plot, Time Series Plot, Scatter Plot) statistical techniques (Hypotheses, Correlation, Regression, ANOVA, Probability...) 5s workplace organisation Vsm Value stream mapping (Current & future) spC statistical process Control msa measurement system analyse Cpk process Capability & performance fmea failure mode effect analysis & Control plan doe design of experiments Kaizen Continuous improvement / pdCa lean simulation game, six sigma case & practice exam the detailed lssa skill set with all subjects and learning objectives can be downloaded from our website. Each participant is provided with two training manuals including presentations and exercises. Participants will also receive a variety of practical templates and the book Applying Lean Six Sigma in Manufacturing by Quentin Brook. During the training we use Minitab. A 30-days trial version can be downloaded at www.minitab.com. Higher education / university level 8 days (within approximately 3 months) Open training 4.250,- p.p. in-company price available upon request Target Group Objectve Content Material Level Duration Price INDUSTRY 24 LEAN SI
LEAN SIX SIGMA BLACK BELTS ARE BOTH PROJECT MANAGERS AND SPECIALISTS. THESE PROFESSIONALS ARE RESPONSIBLE FOR THE DEVELOPMENT OF NEW PRODUCTION AND IMPROVEMENT PROCESSES. LEAN SIX SIGMA BLACK BELTS ARE CAPABLE OF SUCCESSFULLY INTRODUCING CHANGE. Lean Six Sigma Black Belt Lean Six Sigma Green Belt design, process and quality engineers, project managers, production and quality managers.
On completion of Lean Six Sigma Black Belt training, you will be able to structurally and effectively identify and solve problems. You will be able to manage improvement and decisive change projects. the result is improved process performance and better product quality which translates into lower costs and higher customer satisfaction. lean principles (Value, Value stream, flow, pull, Continuous improvement) project management (project Charter, hoshin, policy deployment, dmaiC, ..) production management (toC, tpm, oee, smed, ..) Voice of the Customer & Ctq flowdown process performance metrics & process management (pfm, sipoC, Vsm) extended minitab training problem solving (8d, Cause & effect, 5Why, ..) advanced spC statistical process Control advanced msa measurement system analysis Cpk process Capability & performance design for excellence (dfm/a, dfss, reliability eng., tolerance analysis, ..) dfmea / pfmea failure mode & effect analysis & Control plan set-up and implementation of experiments using design of experiments (DOE, RSM, ..) statistical analysis (non-normal data, multiple regression, transformations, ..) analysing attribute data (Chi-square, attributive agreement, ..) project selection & project tracking Cap Change acceleration process & human dynamics lean simulation game, six sigma cases & practice exam the detailed lssa skill set with all subjects and learning objectives can be downloaded from our website. Each participant is provided with three training manuals including presentations and exercises. Participants will also receive a variety of practical templates and the book Applying Lean Six Sigma in Manufacturing by Quentin Brook. During the training we use Minitab. A 30-days trial version can be downloaded at www.minitab.com. Higher education / university level 8 days (within approximately 3 to 4 months) Open training 7.950,- p.p. in-company price available upon request Target Group Objectve Content Material Level Duration Price INDUSTRY & FOOD INDUSTRY 25 Product development PRODUCT DEVELOPMENT 26 LEAN SI PRODUCT DEVELOPMENT Product development
MAP POTENTIAL FAILURE MODES AND THEIR EFFECTS USING A STRUCTURED RISK ANALYSIS. WE INVESTIGATE THE CONSEQUENCES AND IMPACT OF POSSIBLE FAILURES IN A PRODUCT OR PROCESS BY CREATING AN FMEA. AN FMEA ALLOWS YOU TO PREVENT OR DETECT POTENTIAL FAILURES AND TAKE THE CORRECT STEPS IN AN EARLY STAGE TO AVOID THEM. MORE AND MORE INDUSTRIES HAVE MADE THIS A REQUIRED STEP IN THE RELEASE OF A NEW PRODUCT OR PROCESS. FMEA - Failure Mode Effect Analysis Designers, manufacturers and engineers responsible for product and process development. On completion of this training you will be able to set up a Design FMEA for new product designs and a Process FMEA for new processes. We also discuss some common methods used for trouble shooting and problem solving. Finally, we make a control plan (management plan) and a mitigation plan (improvement plan).
application of fmea in quality systems such as qs 9000, ISO/TS 16949 and DIN 25448 different types of fmeas: system fmea, design fmea and process fmea links to quality function deployment (qfd) and functional requirements systematic divide of a product or process into unique parts modelling and naming functions Creation of a design fmea Creation of a process flow map identify sources of risk Creation of a process fmea guidelines for rating severity, occurrence & detection assessing rpns (risk priority number) root Cause analysis: Cause & effect matrix, failure tree analyses and 5Why Creation of Control plan Each participant is provided with a training manual including all presentations and exercises. Participants will also receive a number of Excel FMEA templates. During the training we use Excel. Secondary vocational education or higher 2 days in-company price available upon request Target Group Objectve Content Material Level Duration Price GOVERNMENT LOGISTICS INDUSTRY 27 LEAN SI
DESIGN OF EXPERIMENTS IS AN EFFICIENT WAY FOR DESIGNING AND CONDUCTING EXPERIMENTS. IT DIFFERS FROM THE CONVENTIONAL METHOD MAINLY IN THAT IT ALLOWS NOT ONLY MAIN EFFECTS BUT ALSO INTERACTIONS BETWEEN EFFECTS TO BE VISUALISED. IN ADDITION, DECISION MAKERS ARE ABLE TO DRAW RELIABLE CONCLUSIONS WITH FEWER EXPERIMENTS. THIS IS POSSIBLE WITH THE CLEVER USE OF FRACTIONAL EXPERIMENTS AND THE RESPONSE SURFACE METHOD. DOE - Design of Experiments Designers, manufacturers and engineers responsible for product or process development and optimisation. On completion of this training, you will be able to perform more efficient and targeted experiments. In addition to the main effects, you will also gain insight into interactions. Employing DOE will lead to lower research costs and faster results with statistically grounded conclusions. minitab introduction ofat (one factor at time) vs. doe 2k full factorial experiments preparing transfer functions residual analysis fractional factorial experiments repetitions vs. replicates linear models vs. Curvature rsm response surface method Central Composite & BoxBehnken plackettBurman taguchi robust design sequential experiments and path of steepest ascend Each participant is provided with a training manual including all presentations and exercises. During the training we use Minitab. A 30-days trial version can be downloaded at www.minitab.com. Higher education / university level 2 days in-company price available upon request Target Group Objectve Content Material Level Duration Price INDUSTRY 28
DOE - Design of Experiments PRODUCT DEVELOPMENT DESIGN FOR SIX SIGMA EXPERTS ARE RESPONSIBLE FOR THE DEVELOPMENT OF NEW PRODUCTS AND PROCESSES. THROUGH THEIR EXTENSIVE KNOWLEDGE OF THE STRUCTURED DFSS METHODOLOGY AND LEAN SIX SIGMA TOOLS, DESIGN FOR SIX SIGMA EXPERTS ARE ABLE TO ACHIEVE HIGHER PRODUCT QUALITY AND SMOOTH PRODUCT LAUNCHES. DfSS - Design for Six Sigma designers, constructors, engineers and project leaders who are responsible for product or process development. Applying the Lean Six Sigma instruments and the structured DfSS approach results in fewer product launches and and provides insight into product life expectancy. the pCp process (product Creation process) project management (project Charter, dmaiC, dmadV, idoV, ..) design for excellence (dfm/a, dtC, poke yoke) qfd introduction quality function deployment dfmea / pfmea failure mode & effect analysis measurement system analysis (msa advanced) Voice of the Customer & Ctq flowdown Cpk process Capability & performance process management, Cause & effect reliability engineering & tolerance analysis designing and implementing experiments using design of experiments (DOE, RSM, ..) statistical analysis (hypothesis, Correlation, regression, anoVa, spC, Probability, Non-normal data, Multiple Regression, Transformations, ..) Each participant is provided with two training manuals including presentations and exercises. Participants will also receive a variety of practical templates and a helpful Lean Six Sigma book. During the training we use Minitab. A 30-days trial version can be downloaded at www.minitab.com. Higher education / university level (with statistical knowledge) 8 days (within approximately 3 months) Open training 4.750,- p.p. in-company price available upon request Target Group Objectve Content Material Level Duration Price INDUSTRY 29 Certification CERTIFICATION 30 LEAN SI CERTIFICATION Certification
IN PARTNERSHIP WITH THE EUROPEAN CERTIFICATION AND QUALIFICATION assoCiation (eqCa ), the lean siX sigma aCademy (lssa) and the uniVersity of tWente (ut), We offer the opportunity to oBtain european CertifiCation. LSSA - Lean Six Sigma Academy Lean Six Sigma consists of four distinct levels. The training level that suits you best depends on your role in the improvement process. The table below can be used as a guideline: LSS Belt Level Education Level Improvement Process Role Yellow Belt All levels Anyone who wants to learn basic Lean Six Sigma principles and the most important Lean Six Sigma instruments. Orange Belt Secondary vocational education Anyone who is directly or indirectly involved in process improvement in his / her own work environment or as a team member of a larger project. Green Belt Higher vocational education / university level Department managers, engineers, process engineers and process managers working on process improvement as team members or project leaders. Black Belt Higher vocational education / university level and field experience project managers, department managers, senior engineers, process engineers and consultants working on process improvement as project managers. The mission of the LSSA is to provide guidelines for the four central European Lean Six Sigma belt levels and to facilitate the examinations. LSSA is classified in classified in the European Certification and Qualification Association (ECQA), a non-profit organisation that was established more ten years ago. Lean Six Sigma training courses are based on the LSSA skill sets which are based on the American ASQ guidelines and are supplemented with Lean, TOC and TPM learning elements. These skill sets provide a detailed description of the learning elements that a participant will have acquired after completing the training program. The level upon which these learning elements may be applied is also described. The LSSA skill sets can be downloaded from www.LSSA.eu or www. symbolbv.com There are two possibilities for Green and Black Belts certification: option a - theoretical green Belt / Black Belt certificate: Only theoretical exam option B - full green Belt / Black Belt certification: theoretical exam + two practical projects the complete lean six sigma certificate requires sufficient achievement in both theoretical and practical elements. If you complete the theoretical exam before you complete your projects, your result will stay valid for two years during which time you can submit your two lean six sigma projects for review. please note however, that disconnecting the theory and the project assessment is considered a re-take and is subject to two separate exam fees. 31
IN PARTNERSHIP WITH THE EUROPEAN CERTIFICATION AND QUALIFICATION assoCiation (eqCa) and the lean siX sigma aCademy (lssa) We offer the OPPORTUNITY TO OBTAIN EUROPEAN CERTIFICATION AS A YELLOW BELT OR ORANGE BELT. THIS IS A THEORETICAL EXAM. THE EXAM IS TAKEN ONLINE AT WWW.ECQA.ORG.
Yellow / Orange Belt Certificating
Anyone who has followed a Yellow Belt or Orange Belt training program. the content of the theoretical exam is based on the lean six sigma skill sets (Yellow Belt / Orange Belt) which can be downloaded from www.LSSA.eu the exam includes a theoretical test and a short assignment a calculator or excel is needed to answer some questions the exam is in english it is an open book exam meaning you can use your book and training material in the exam the exam is comprised of 45 multiple choice questions you must obtain at least 29 correct answers The Exam Guide with all exam instructions can be downloaded from www.LSSA.eu. To enrol in the exam, please contact Symbol. Followed the Yellow Belt or Orange Belt training program Half-day 150 - p.p. Online Target Group Theoretcal Exam Level Duration Price Locaton 32 LEAN SI
IN PARTNERSHIP WITH THE EUROPEAN CERTIFICATION AND QUALIFICATION assoCiation (eqCa), the lean siX sigma aCademy (lssa) and the uniVersity of tWente (ut), We offer the opportunity to oBtain european CertifiCation AS A GREEN BELT OR BLACK BELT. Green / Black Belt Certificating Yellow / Orange Belt Certificating
Anyone who has followed the Green Belt or Black Belt training program. the content of the theoretical exam is based on the lean six sigma skill sets (Green Belt / Black Belt) which can be downloaded from www.LSSA.eu. the exam is in english you are permitted to use your book and training material in the exam the answers to some questions require the use of minitab or any other statistical software the exam is comprised of 60 multiple choice questions you must obtain at least 40 correct answers personal identification is required the theoretical exam is entitled to 5eC (european Credits) practical projects are assessed by lssa accredited master Black Belts. We encourage you to have your project charter assessed in an early stage. you are not required to present your projects unless your Champion requires you to do so. you must submit two lean six sigma projects per person the structure must conform to the dmaiC or dmadV roadmap steps projects must be digitally submitted in the lssa standard review template (PowerPoint with approximately 25 slides). green Belt saving / cost avoidance is at least 20,000 per project per year Black Belt Belt saving / cost avoidance is at least 50,000 per project per year project must be signed-off by the Champion and financial Controller projects must be written in english The Exam Guide with all exam instructions can be downloaded from www.LSSA.eu. You can enrol for the exam by contacting Symbol. You must also specify if you will take the Service exam or the Manufacturing exam. Followed the Green Belt or Black Belt training program Half-day 350 - p.p. Online or at the University of Twente (the Netherlands) Target Group Theoretcal Exam Practcal Exam Level Duration Price Locaton CERTIFICATION 33 Registraton a. afer registraton, you will receive an email confrming your registraton. online applicatons are confrmed with an order confrmaton. b. approximately one week before the training, you will receive an invitaton and locaton directons. Cancellaton and Rescheduling a. registraton cancellatons are possible only by contactng symbol directly. afer doing so, you will receive a writen cancellaton confrmaton from symbol. only this document serves as proof of cancellaton. if you do not receive a cancellaton confrmaton email, you are responsible for contactng us to obtain this document. b. Cancellatons are accepted with a full refund up to 30 days prior to the frst day of the training programme or training day. Cancellatons made with less than the 30 days notce before the training programme start date or training day will be charged 50% of the total training fee. c. afer the start date of the training programme, cancellaton is no longer possible. in consultaton with symbol, an alternatve training may be followed with the same training requirements. d. For open training Symbol reserves the right to cancel trainings, to change training locatons, and to modify training content for any reason. in such a case, we will contact you. if the change of locaton or content does not work for you, you may cancel free of charge. Examinaton Rules a. those partcipatng in an examinaton are subject to the examinaton requirements of the certfcaton body. b. personal identfcaton is required for all those partcipatng in an examinaton. c. the name and birth date on the certfcate will appear as writen on the registraton form. Invoices a. All prices shown are excluding VAT taxes. b. Billing for mult-day sessions take place in the week the training starts. c. Payment is due within 30 days from the date appearing on the invoice. d. The billing address used will be that which was provided on the registraton form. e. If you would like a purchase number included on the invoice, this should be indicated on your registraton form. OUR SERVICES AND TRAINING ARE SUBJECT TO TERMS AND CONDITIONS AS FILED WITH THE TRADE REGISTER. THE FOLLOWING IS A CONDENSED SUMMARY OF OUR TERMS AND CONDITIONS: TERMS & CONDITIONS Terms & Conditions P R O C E S S I M P R O V E M E N T UTRECHT Graadt van Roggenweg 328 3531 AH Utrecht The Netherlands T +31 (0)30-7118853 ENSCHEDE Institutenweg 26 7521 PK Enschede The Netherlands T +31 (0)53-2030240 F +31 (0)53-2030241 info@symbolbv.nl www.symbolbv.nl