Module 1: Define Phase

This module covers the foundational concepts of Six Sigma and Lean, emphasizing:

• The origins and principles of Six Sigma and continuous improvement.
• Developing a project charter, defining processes, and identifying Critical-to-Quality (CTQ) characteristics.
• Utilizing tools like Pareto Analysis and metrics such as Defects Per Unit (DPU) and Defects Per Million Opportunities (DPMO) to quantify the Cost of Poor Quality (COPQ).

Module 2: Measure Phase

This module focuses on measuring the current performance of processes:

• Identifying key process input and output variables.
• Collecting and validating data for accurate analysis.
• Using measurement tools such as process capability analysis and data visualization techniques.
• Calculating baseline metrics to establish the starting point for improvement.

Module 3: Analyze Phase

This module dives into identifying the root causes of process issues:

• Performing root cause analysis using tools like Fishbone Diagrams and 5 Whys.
• Conducting hypothesis testing to validate assumptions.
• Applying statistical techniques such as regression analysis and correlation to uncover patterns and relationships.

Module 4: Improve Phase

This module emphasizes developing and implementing solutions to address identified issues:

• Brainstorming and prioritizing improvement ideas.
• Designing experiments and testing solutions for effectiveness.
• Leveraging Lean tools like Kaizen and Value Stream Mapping to streamline processes.
• Implementing solutions while ensuring minimal disruption to operations.

Module 5: Control Phase

The final phase focuses on sustaining improvements over time:

• Monitoring processes with tools like Control Charts (I-MR, Xbar-R, P-chart) and Statistical Process Control (SPC).
• Designing control and response plans to manage process variations.
• Conducting cost-benefit analyses to ensure long-term sustainability of improvements.
• Embedding continuous improvement practices into organizational culture.