Lean Six Sigma for Manufacturing Excellence
This course combines the power of the two leading process improvement methodologies — Lean Manufacturing and Six Sigma — to focus on process improvement. Value stream mapping is used to define the current state of any process or product line with all its problems and opportunities; then, a future state vision is created with the problems corrected and the opportunities applied. Once you know where a process is and where you’d like it to be, you can develop a detailed plan with specific actions to achieve the improved future state. Apply the Lean concepts of Kanban pull systems, cycle time reduction, level mix model production, mistake proofing, standard work and Kaizen to your Six Sigma DMAIC projects.
You’ll learn to:
- Value-stream map the current material and information flows of a process or product line and identify problems and opportunities for improvement
- Brainstorm a future state map and create a common vision for the organization
- Combine Lean Manufacturing and Six Sigma tools and concepts to transform a process from its current state to the future vision
- Practice implementing Kaizen process improvement projects
- Calculate cost savings for a process improvement project and leverage those savings throughout the organization
- Use Lean and Six Sigma in a controlled lab with hands-on factory simulations and exercises
Outline
Introduction to Lean Six Sigma
- Lean history
- Lean concepts
- Hands-on simulation of non-Lean process
Assessing Current Processes and Creating a Vision
- Value stream mapping
- Kanban systems
- Push vs. pull
- Takt and cycle times
- Brainstorming techniques
Process Improvements
- Line balancing, standardized work and single piece flow
- Kaizen events
- Six Sigma techniques
- Poka Yoke
- Quick changeover (SMED)
- Preventative maintenance
- Hands-on simulation of a Lean process
- Exercise: using Lean and Six Sigma techniques
Creating Actionable Plans
- Setting a work environment for process improvements
- Success stories and best practices
- Exercise: plan development
Schedule
Evening before course — Optional dinner for those arriving early
Day 1 — 8:00 a.m – 8:30 a.m. Registration
Day 1 — 8:30 a.m – 4:30 p.m. Registration/Session
Day 2 — 8:00 – 3:30 p.m. Session
Day 3 — 3:30 p.m. Exam
Program faculty
Robert L. Olson
Bob has more than 30 years of experience in the applying and training of process improvement techniques for problem solving, quality improvement, process management, project implementation and cost reduction.
As a training professional, Olson has developed process improvement training for various manufacturing and service professionals, both in hours and through colleges/universities. Specific training includes Six Sigma Green Belt, Lean manufacturing, 5S, value stream mapping, statistics and problem solving for improvements in productivity, quality and workflow.
Bob has provided engineering support in quality and process improvements for multiple production and service industries. He has increased production and quality yields with Design of Experiment and other statistically based process improvement techniques.
Bob earned a B.S. in Chemical Engineering and is a registered Professional Engineer (PE) in North and South Carolina. He is an ASQ-certified Six Sigma Black Belt.
“Because I was so impressed with the first executive education course I took at the University of Wisconsin-Madison, I came back for a second one! The valuable knowledge I walked away with has served me well in all of my work-related roles. I’m looking forward to earning a professional certificate from this recognized and respected educational institution — not only will a certificate demonstrate my dedication to personal enrichment, but it will also help me expand my job responsibilities and, in the long term, further my career.”
David Chatterton, Project Manager, Northern Engraving, Sparta, WI
The University of Wisconsin-Madison, as a member of the University Continuing Education Association (UCEA), authorizes this course for 1.4 Continuing Education Units (CEUs) or 14 hours.