LEAN SIX SIGMA GREEN BELT
In collaboration with
Accredited by
International Association for Six Sigma Certification THE UNIVERSAL CERTIFICATION
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LEAN SIX SIGMA GREEN BELT
INTRODUCTION An important component to ensure success of Six Sigma Quality Implementation is to have team members who can support the work of the Black Belts. Green Belts are people work directly with the black belts but do not have the same level of training or responsibility to the project as the black belts. Given the nature of the tasks Green Belts most often execute, these individuals should receive training which focus on the Define, Measure, and Analyze phases of the Six Sigma DMAIC (Define, Measure, Analyze, Improve, Control). COURSE OUTLINE 1. Practical application of statistical concepts learned is afforded through case studies, hands on exercises & assigned projects. This will need minimum 3 days training on Statistics 2. Application of DMAIC (Define, Measure, Analyze, Improve, Control) and data collection to support the selection and completion of a project. This needs 1 day training 3. Selected Training such as: a. Design of Experiments b. Variance Analysis & ANOVA c. SPC DEFINE PHASE: DAY 1-2
INTRODUCTION OF SIX SIGMA ROADMAP
PROJECT SELECTION GUIDELINES Determine project scope and boundaries Must define problem statement Projected annualized savings Project metrics, Baseline and Entitlement (target saving per project)
PROJECT DELIVERABLES
INTRODUCTION TO STATISTIC SOFTWARE, MINITAB
CAUSE & EFFECT ANALYSIS Cause and Effect Matrix Fishbone Diagram
BASICS MINITAB PRACTICE SESSION
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COURSE OUTLINE (continuation) MEASURE PHASE: DAY 3-6
FAILURE MODE EFFECT ANALYSIS (FMEA) Brief explanation on FMEA principle and techniques Summarize the definitions, concepts, application options and relationships with other tools
BASIC STATISTICS Describe mean, median, quartiles, mode, standard deviation, range from the data analysis Define variability in a process Work with variability (graphically and numerically) Normality Test Check data normal or non-normal Normal Probability Plots
MEASUREMENT SYSTEM ANALYSIS Understand that Measurement is a Process Compare Measurement System Variability to Process Variability Identify and quantify the sources of Measurement Variability Discover opportunities for Measurement System and Total Process Variability improvement
PROCESS CAPABILITY STUDY Understand the need for Process Capability study Quantify Process Capability (long and short term)
ANALYZE PHASE: DAY 7-9
OVERVIEW AND BRIEF INTRODUCTION ON PROBABILITY DISTRIBUTION (TYPE AND PLOTTING WITH MINITAB)
Basic nature of data Discrete Probability Distributions Discrete Uniform Distribution Binomial Distribution Continuous Probability Distributions Continuous Uniform Distribution Normal or Gaussian Distribution Exponential Distribution
SAMPLE SIZE SELECTION
INTERVAL OF ESTIMATION
CENTRAL LIMIT THEOREM
HYPOTHESES TESTING (VARIABLES & DISCRETE) Apply various tests such as 1 sample Z test, 1 sample T test, 2 samples T test, 1 proportion Test, 2 proportions Test to compare different populations.
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COURSE OUTLINE (continuation)
ANOVA (ANALYSIS OF VARIANCE) What is ANOVA? What is the ‘Sum of Squares’? Calculate the test statistic Epsilon Squared ANOVA by example Contingency Table
CORRELATIONS & REGRESSION Correlation Create Scatter Plots Perform simple Linear Regression Coefficient of Correlation (R, R2 and adjusted R2) Regression diagnostics
IMPROVE PHASE: DAY 10-11
INTRODUCTION TO DOE (DESIGN OF EXPERIMENT) What is DOE To optimize the process variables DOE Planning
FULL FACTORIAL Describe a full factorial experiment Define what it meant by factors & levels and explain the notation used for a full factorial experiment design Explain main effects and interactions Set up and Analyze full factorial experiment using Minitab
2K FACTORIAL DESIGN Why do we need to use 2k factorial experiments? 2k Vocabulary & Terminology Steps for DOE Analysis 2k Standard Order Designs Calculating main effects Calculating interactions Adding Center Points Adding Blocking 2k Example and Exercise (with Minitab and other related software)
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COURSE OUTLINE (continuation) CONTROL PHASE: DAY 12-14
INTRODUCTION TO CONTROL Introduction to process monitors and controls Introduction to current management tools and philosophies Determine the effects of the informal system
SPC 1 (VARIABLE CHARTS) Introduction to SPC Why we need Statistical Process Control Implementation and Theory Control Charts for continuous data X-bar and R charts Subgrouping and frequency Control Chart interpretation Reaction to Out-of-Control Situations Other Shewhart charts for continuous data Control Charts for discrete data P, NP, C, and U charts
SPC 2 (ATTRIBUTE CHARTS) Attribute Terminology Discrete or “Attribute” types of data Defect and Defective
ERROR PROOFING Explain the value of error proofing Describe situations where error proofing is needed Implement error- proofed systems
MAINTAINING THE GAINS Understand why 5S Workplace Organization is a key factor in maintaining success Learn techniques for building organizational memory to make improvements permanent
WHO SHOULD ATTEND This workshop is designed for six sigma improvement team members, supervisors and other executives who will be conducting Six Sigma projects in the lower complexity than the Black Belt projects.
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TRAINER’S PROFILE 1 FUAD MOHAMAD IDRIS has an extensive experience of over 14 years in Electronic Manufacturing and 7 year experience in Product Development. He has a degree in Bachelor of Science (B. Sc.) in Mechanical Engineering from Northern Arizona University, United States in 1989. He started his career as a Field Engineer in Schlumberger Overseas S.A in 1990. He then joined Motorola Penang as a SMT Equipment Engineer in 1991. In the 21 plus years in Motorola, Fuad had held various responsibilities; as a SMT Equipment Engineer, an Automation Engineer, an Engineering Manager, a Lean Manufacturing champion, a Consultant Black Belt and Technical Lead in Reliability Engineering, before becoming a full time consultant in Lean Six Sigma in 2013. Throughout his careers, he has acquired in-depth knowledge & practical experiences in the areas of SMT, automation, failure analysis, problem solving, process characterization, process optimization, productivity improvement, product design optimization & product reliability. Fuad is also a certified Motorola's Six Sigma Black Belt since 2002. As a Consultant Black Belt, he has mastered the Motorola Six Sigma methodologies & statistical tools and applications with hands-on experience in Six Sigma for Process Improvement (SSPI-DMAIC model) & Six Sigma for Product Development (SSPDCDOV model i.e. DFSS) while working in Motorola Penang. He was also a certified trainer for the Six Sigma training curriculum for Motorola University. Fuad has trained, mentored and coached over more than 20+ Black Belts, 100+ Green Belts and providing Six Sigma training to more than 1,000+ engineers for the last 10 over years. Based on his Six Sigma involvement in Motorola as a mentor, as a coach, as a trainer & as a consultant, he has contributed to more than US$10million cost saving and cost avoidance to the organizations. As to date, Fuad also has provided numerous training courses & consultancy works to Motorola Penang, Motorola Taiwan, Motorola Bangalore-India, Motorola Singapore, MIMOS Berhad, UTEM-Melaka, Collaborative Research in Engineering Science and Technology (CREST) Center-Penang, Fuji Electric-Kulim, Nichicon-Bangi, Entegris-Kulim and BOSE System-Penang. His breadth of exposures coupled with his ability to interact with employees at all levels and functions in manufacturing and product development organizations makes Fuad an extremely valuable resource for imparting practical Lean Six Sigma knowledge & problem solving skills.
TRAINER’S PROFILE 2 SABRINA LIM has a Bachelor in Engineering (Hons) from The University of Sydney. She was attached to well-known American MNCs where she had hands-on experience in the Quality, Quality Systems and Process Engineering. Her success in her career include ISO9000 recertification, taking responsibility for product transfer from the US, troubleshooting new product quality problems and involvement in in-process yield improvement programmes, developing training materials, calibration systems, new product specifications and standard operating procedures. She has been involved in teaching and training for the past 12 years and has conducted trainings in quality, quality systems and technical areas. Her clients include Western Digital, Motorola Solutions, Renesas Semiconductor, Flextronics Technology, Schott Glass, Western Digital, Jabil Circuits, Sharp Onkyo and others. Her hands-on experience in manufacturing and consulting as well as exposure in training personnel from diverse industries in Malaysia and Singapore enables her to provide a good insight to troubleshooting process problems and improving overall quality as well as latest developments in the quality arena.
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TRAINER’S PROFILE 3 LAI PUI FUN, has a Bachelor in Engineering (2nd Class Upper Honours) from The University of Malaya. She was attached to well-known Local Contract Manufacturing Company for the last 14 years where she had hands-on experience in the Quality, Quality Systems and Process Engineering. Her success in her career include ISO9000 certification, TPM implementation, SPC implementation, taking responsibility to develop quality systems for various procedures and involvement in in-process problem solving and yield improvement programmes, developing training materials, measurement and evaluation systems, new product specifications and standard operating procedures. She has been involved in teaching and training for the past 14 years and has conducted trainings in quality tools, SPC, Poka Yoke, DOE, MSA, quality systems and technical areas. Her hands-on experience in manufacturing as well exposure in training personnel from diverse industries in Malaysia enables her to provide a good insight to troubleshooting process problems and improving overall quality as well as latest developments in the quality arena. Below is list of more popular trainings she conducted currently: 1. 8D 2. FMEA 3. SPC 4. DOE 5. TRIZ 6. Practical Statistical Application in Industry 7. Quality Tools 8. MSA
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TRAINER’S PROFILE 4 MICHELLE NG Job experiences: Working in multinational companies that providing manufacturing services in Semiconductor & Surface Mount Technology (SMT) industries for the last 13 years. Drives Process Control & Quality Assurance/Inspection and coordination of customers’ quality issues with cross-functional team. She is also the champion of quality tools application in the company. Areas she take charged include: FMEA, Reliability Statistics, Design of Experiments and TQM.. Certified to six sigma black belt in 2003. Experienced in assembly processes setup for PCB products and set up ISO/TS16949 Quality Systems. She has been conducting training for in-house employees since 2003 and conducted in-house trainings for companies like Intel, SMI Metals, Caltronics, On-Semi etc in the following topics: Poka-yoke FMEA 6 Sigma overview Design for Six Sigma SPC QC tools Statistics Quality Control Methods ISO 9001/QS 9000 TS16949 implementation Internal Quality Auditing Academic background: Bachelor Degree of Quality Control from Universiti Sains Malaysia, Penang
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TRAINER’S PROFILE 5 SIM LAM THONG (TQC, TPM, TS16949, Cost Reducing Consultant) has more than 28 years of vigorous involvement in TQC/TPM/TS16949 activities, Statistical Application, Maintenance Techniques, GD & T, Problem Solving and Project Management training. He has a lot of "Hands on" and practical experience on SPC/TQC/TPM/TS16949 implementation, statistical application for industry’s measurement and part tolerancing, 5S/TQC/TPM audit and providing in-house consultation services to many local and overseas companies.
quality Implementation, Productivity and TPM training/consultation, Industrial Statistics Application and Design of Experiments Training and implementation. He has vigorously involved in implementing and developing TQC/TPM/TS16949 Activities in many local multinational and has presented many technical working papers in local and international Quality Conventions such as ICQCC in Hong Kong, Japan and others. He has been conducting training for many multinationals such as Renesas Semiconductor, Hitachi Metals, Hitachi Consumer Products(KL), ICI Products (M) S/B, Hewlett Packard, Acer Computers, Mabuchi Motors, VDO, B. Braun Medical, Fairchild Semiconductor, Motorola Penang, ACM Chemical, Seagate Penang, Hong Yuen (Hong Kong) and many local companies such as Daibochi (M) S/B (Melaka), Malaysian Rubber Gloves, Belton Industries etc. He has also help Hitachi Semiconductor and Hewlett Packard (M) S/B won the Malaysian National Champion in National QCC Convention in 1995, 1996 & 1997. He also helps Agilent Technologies (M) Sdn. Bhd. Achieving TPM Excellent Award in 2000, with certification from JIPM (Japan Institute of Plant Maintenance). After 2000, he has been working as a productivity and quality consultant for many local companies as listed below. Prior to working as a consultant he has been working as a TPM/TQM Manager for a large multinational electronic components assembly company for 18 years. He has been actively working with engineers to solve engineering and designing problems and application of statistics. He is currently the TQC/TPM/TS16949, Six Sigma Quality, Statistics, 5S and Management Consultants for Shin Etsu Handotai (Shah Alam), Infineon (Melaka), Min Aik (Melaka), Public Packages Penang, Agilent, Samsung Corning, Dorma (M) Sdn. Bhd., Unisem, Linear Semiconductor, Tessy Plastics (Shanghai), SAM Group of Companies, Diethlm Aluminium Works (Singapore), Matsushita Electronic Motor, Carsem Semiconductors. Area covered including Total Productive Maintenance (TPM), TQC/TS16949, Measurement Uncertainty & Calibration implementation, Statistical application for 6 sigma and Continuous Improvement. Also, he has been a 5S consultant for Malayan Flour Manufacturing (MFM) Groups of companies. He possesses a B.Sc. Ed. (Hons.) (Mathematics/Physics) and M. Sc. (Taguchi Experimentation ) both from USM, Penang. He can communicate in English, Bahasa Malaysia and Mandarin with major dialects such as Cantonese and Hokkien. DURATION 14 days COURSE FEE PSDC Members: Non-Members:
RM 5,000/pax RM 5,300/pax
IASSC Six Sigma Black Belt certification:
USD 395/pax
*All prices listed above are subjected to GST effective 1st April 2015
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DATES April: May: June: July: Aug: Sep: Oct:
11 & 25 9 & 23 13 & 27 4 & 25 1 & 15 5 & 19 10 & 24
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ADMINISTRATIVE DETAILS
Venue
PSDC
Payment
Cross cheque made payable to “PENANG SKILLS DEVELOPMENT CENTRE” one week before commencement date.
Registration
Registration forms together with payment to be forwarded to:PSDC 1, Jalan Sultan Azlan Shah, Bandar Bayan Baru, 11900 Bayan Lepas, Penang. Tel: 04-643 7909 Fax: 04-643 7929 Email:
[email protected]
Cancellation
PSDC reserves the right to cancel or postpone any program but with due notice to the company(s)
Refund
Fees will only be refunded in full for any cancellation of registration provided written notice is received 7 working days before commencement date. Substitute attendee(s) will be accepted at no extra charge. For further information, please contact Nur Liyana (ext. 579) Email:
[email protected] Online registration: http://www.psdc.org.my
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