IBM Global Business Services
Lean (Six) Sigma Training program in detail August 2008 / V.4,2 Frank Bornhoeft (IBM GBS)
© Copyright IBM Corporation 2008
IBM Global Business Services
IBM Lean Sigma trainings Location: all trainings are conducted at IBM Frankfurt Green Belt (GB) Training (6 day incl. Courier simulation. Optional exam) dates see internet page Black Belt (BB) Training (3 x 5 days incl. exam and Courier simulation) dates see internet page Courier Simulation (1 day) dates see internet page Registration/ costs Your contact person for registration is Frank Bornhoeft (
[email protected]) costs for GB participant 4.000 EUR costs for BB participant 10.500 EUR costs for Courier participant: 450 EUR Maximum number of participants for GB/BB training: 16 IBM Lean Sigma Internet page: http://www-935.ibm.com/services/de/index.wss/summary/gbs/n1628627
In addition to these standard trainings, IBM offers customers to customize this Lean Sigma training modules for individual requirements 2
IBM GBS | Lean Sigma Training in detail | 12-Aug-08
© Copyright IBM Corporation 2008
IBM Global Business Services
The modular Lean Sigma service portfolio is aligned with the critical success factors for a Lean (Six) Sigma implementation
IBM Lean Sigma service portfolio
Relevant Successfactors
Strategy
Structure
Knowledge
Strategic Business Assessment
Goal/Incentive system adaptation
Exec Training/ Workshop
Integration with HR (HR development)
Black Belt Training
Project Selection (Scoping) BB/GB candidate Assessment Definition of approach Integration with CMMI, ISO and ITIL
Implementation
Setup program reporting
Champion Training Benefit reporting/ tracking
Green Belt Training Benefit guidelines
Setup process management
Yellow Belt Training
(Coaching) program management
“Courier” Simulation Lean Sigma Exam Lean Sigma certification
Project realization Project Coaching
IBM Lean Sigma Consultants are Six Sigma (Master/ Black Belts) as well as Lean Management Experts. We provide DMAIC, DFSS and DMEDI (Lean) training + coaching. Green marked service packages are part of our proposal. Yellow marked service packages are included in our Black Belt training.
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IBM GBS | Lean Sigma Training in detail | 12-Aug-08
© Copyright IBM Corporation 2008
IBM Global Business Services
The Six Sigma Roles Champion
Sponsor
Senior Management/ Board
Assures availability of required resources Observes regular program status updates
Program Manager
Initiator of Lean Sigma Project (Project Sponsor)
Senior Manager/ Board Member
Assures availability of required resources
Project support with Lean Sigma Expertise and Methodology
Manages the Change
Manages Lean Sigma Program Office and Program
Monitors project progress
Controller
Process Owner
Black Belt
Master Black Belt
Green Belt
Own processes Take over process after project handover. Team member
Yellow Belt
Mentors Black Belt or Green Belt
Leads Lean Sigma Projects
Project Lead of small Lean Sigma Projects
Core Team member in Lean Sigma Projects
Conduct Trainings
Looks after and support the projects
Is member of Lean Sigma Projects
Full Time project support
Is responsible for project planning and execution
Is freed up from his daily business for project work (~40%, depending on project workload)
Is freed up from his daily business for project work (~20%)
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Financial control of the Lean Sigma projects Controlling-support in Project definition, selection and project implementation
Performs as a coach for the project members
IBM GBS | Lean Sigma Training in detail | 12-Aug-08
© Copyright IBM Corporation 2008
IBM Global Business Services
Overview Black Belt training Week Week 11
Week Week 22
Week Week 33
DEFINE DEFINE MEASURE MEASURE STATISTICS STATISTICS
ANALYZE ANALYZE STATISTICS STATISTICS
Stat. Stat. Tool Tool MINITAB MINITAB or or SigmaXL SigmaXL
Stat. Stat. Tool Tool MINITAB MINITAB or or SigmaXL SigmaXL
Stat. Stat. Tool Tool MINITAB MINITAB or or SigmaXL SigmaXL
11 day day SOFT SOFT SKILL SKILL
11 day day SOFT SOFT SKILL SKILL
11 day day SOFT SOFT SKILL SKILL
IMPROVE IMPROVE CONTROL CONTROL
Remark: about 4 weeks project work between each module 5
IBM GBS | Lean Sigma Training in detail | 12-Aug-08
© Copyright IBM Corporation 2008
IBM Global Business Services
Black Belt Week 1 Monday Monday
Tuesday Tuesday
DEFINE DEFINE ■ ■
■ ■ ■ ■ ■ ■ ■ ■
■ ■
Participants Participants introductions introductions Organisation Organisation Intro Intro Six Six Sigma Sigma Intro Intro to to Define Define Validate Validate Business Business Opportunity Opportunity Process Process documentation documentation
■ ■
■ ■
■ ■
■ ■
DEFINE DEFINE
LEAN/Measure LEAN/Measure
Define Define Customer Customer Requirements Requirements Managing Managing the the project project Preparing Preparing aa project project storystoryboard board Tollgate Tollgate reviews reviews
■ ■
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LEAN LEAN Management Management
Thursday Thursday
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■ ■
Introduction Introduction to to Measure Measure Determine Determine What What to to Measure Measure Intro Intro Minitab Minitab
■ ■
■ ■
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SOFT SOFT SKILLs SKILLs
■ ■
Change Change Mgmt Mgmt Team Team building building
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IBM GBS | Lean Sigma Training in detail | 12-Aug-08
Friday Friday MEASURE MEASURE
MEASURE MEASURE
■ ■
■ ■
■ ■
6
Wednesday Wednesday
Manage Manage Measurement Measurement Data Data Display Display Understanding Understanding Variation Variation Statistics Statistics exercises exercises
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SOFT SOFT SKILLs SKILLs
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Effective Effective Meetings Meetings Stakeholder Stakeholder analysis analysis & & communication communication
■ ■
Determine Determine Sigma Sigma Performance Performance Deliverables Deliverables Measure Measure Test Test Define Define ++ Measure Measure Tools Tools & & Templates Templates for for project project work work Conclusion Conclusion
© Copyright IBM Corporation 2008
IBM Global Business Services
Black Belt Week 2 Monday Monday
Tuesday Tuesday
ANALYSE ANALYSE
■ ■
■ ■ ■ ■
■ ■
■ ■
■ ■
ANALYSE ANALYSE
Introduction Introduction ++ Organisation Organisation
■ ■
Intro Intro to to Analyse Analyse Process Process Stratification Stratification Potential Potential Root Root Causes Causes Validate Validate Root Root Causes Causes
Capital Capital Courier Courier Management Management Simulation Simulation Round Round II ++ IIII (+III) (+III)
Wednesday Wednesday
Thursday Thursday
SOFT SOFT SKILLs SKILLs
■ ■
■ ■
Coaching Coaching Personal Personal effectiveness effectiveness Leadership Leadership & & motivation motivation
Multiple Multiple Variable Variable
ANALYSE ANALYSE IMPROVE IMPROVE
ANALYSE ANALYSE
■ ■
■ ■
■ ■ ■ ■
Friday Friday
■ ■
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Non-parametric Non-parametric tests tests Correlation Correlation and and Regression Regression Lean Lean Toolbox Toolbox Sigma Sigma XL/ XL/ Minitab Minitab Exercise Exercise
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Optional: Optional: Supply Supply Chain Chain Simulation Simulation “Beer “Beer Game” Game”
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Analyse Analyse Quiz Quiz Intro Intro to to Improve Improve (X-Y (X-Y Matrix, Matrix, RACI, RACI, FMEA) FMEA) Deliverables Deliverables Analyse Analyse Tools Tools & & Templates Templates Conclusion Conclusion
Analysis Analysis
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IBM GBS | Lean Sigma Training in detail | 12-Aug-08
© Copyright IBM Corporation 2008
IBM Global Business Services
Black Belt Week 3 Montag Montag
Dienstag Dienstag
IMPROVE IMPROVE ■ ■
■ ■
■ ■ ■ ■
IMPROVE IMPROVE
Introductions/ Introductions/ Organisation Organisation Review Review Week2 Week2 Frankfurt Frankfurt airport airport case case study study Generate Generate Ideas Ideas Evaluate Evaluate and and Select Select Solution Solution
■ ■
DOE DOE (Design (Design of of experiments) experiments) introduction introduction
Mittwoch Mittwoch SOFT SOFT SKILLs SKILLs ■ ■
■ ■ ■ ■
DOE DOE
■ ■
DOE DOE case case study study
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Document Document Solution Solution
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■ ■
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Donnerstag Donnerstag
Involve Involve Stakeholder Stakeholder Conflict Conflict Management Management Coaching Coaching Personal Personal effectiveness effectiveness Leadership Leadership & & motivation motivation
IBM GBS | Lean Sigma Training in detail | 12-Aug-08
Freitag Freitag CONTROL CONTROL
CONTROL CONTROL ■ ■ ■ ■ ■ ■
■ ■ ■ ■
■ ■
■ ■
■ ■
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Validate Validate Solution Solution Plan Plan implement. implement. Implement Implement Solution Solution Control Control Charts Charts Project Project documentation documentation Implement Implement Dashboards Dashboards Control Control & & Response Response Plan Plan Hand Hand Over Over to to Process Process Owner Owner Project Project Benefit Benefit calculation calculation
■ ■ ■ ■ ■ ■
■ ■
■ ■
■ ■
■ ■
Monitor Monitor solution solution Project Project Closure Closure Management Management summary summary Lessons Lessons Learned Learned Test/Examen Test/Examen Tools Tools & & Templates Templates Conclusion Conclusion
© Copyright IBM Corporation 2008
IBM Global Business Services
Green Belt training in detail (6 days + exam) Montay Montay Intro Intro ++ DEFINE DEFINE
Tuesday Tuesday MEASURE MEASURE
Wednesday Wednesday ANALYSE ANALYSE
Thursday Thursday IMPROVE IMPROVE
Friday Friday CONTROL CONTROL
day day 11
day day 22
Project Project
Courier Courier Simulation Simulation
Exam Exam (optional) (optional)
certification certification
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IBM GBS | Lean Sigma Training in detail | 12-Aug-08
© Copyright IBM Corporation 2008
IBM Global Business Services
As an alternative IBM offers on customer desire the Green Belt compact training (5 days) Monday Monday
Tuesday Tuesday
DEFINE DEFINE MEASURE MEASURE ■ ■
■ ■ ■ ■
■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■
10
MEASURE MEASURE ANALYSE ANALYSE
Participants Participants introductions introductions Organisation Organisation Lean Lean Sigma Sigma overview overview Intro Intro to to Define Define Customer Customer Requirements Requirements Process Process Docu. Docu. Tollgates Tollgates Intro Intro Measure Measure Intro Intro SigmaXL SigmaXL ++ exercises exercises
■ ■
■ ■ ■ ■
■ ■ ■ ■
■ ■
■ ■
Manage Manage Measurement Measurement Data Data Display Display Determine Determine Sigma Sigma Perform. Perform. Intro Intro Analyse Analyse Determine Determine & & validate validate root root causes causes LEAN LEAN Management Management SigmaXL SigmaXL exercises exercises
Wednesday Wednesday
Thursday Thursday
SIMULATION SIMULATION
■ ■
Courier Courier Simulation Simulation Round Round II Courier Courier Simulation Simulation Round Round IIII
IBM GBS | Lean Sigma Training in detail | 12-Aug-08
CONTROL CONTROL
IMPROVE IMPROVE
■ ■
■ ■ ■ ■
■ ■
Friday Friday
■ ■ ■ ■
■ ■
SigmaXL SigmaXL exercises exercises Generate Generate Ideas Ideas Evaluate Evaluate and and Select Select Solution Solution Validate Validate Solution Solution Implement Implement Solution Solution Control Control Charts Charts
■ ■
■ ■
■ ■
■ ■
■ ■
■ ■
■ ■
Project Project Benefit Benefit calculation calculation Control Control & & Response Response Plan Plan Hand Hand Over Over to to Process Process Owner Owner Project Project Docu. Docu. and and Closure Closure Examen/Test Examen/Test Tools Tools & & Templates Templates Conclusion Conclusion
© Copyright IBM Corporation 2008
IBM Global Business Services
Our Black and Green Belt trainings contain the famous “Courier Simulation” The Courier Simulation is a one-day simulation that comes as close as you can get to a real life process improvement, Six Sigma or Lean Six Sigma experience. It's fun, handson, fast-paced, and is consistently rated by participants as one of their most valuable training experiences. Developed first for General Electric Capital Corporation, the simulation has been enthusiastically received by the world's largest corporations. The Courier Simulation is designed to achieve breakthrough thinking with everyone who is critical to process improvement - from senior executives to salespeople to support staff to the service professionals who deal directly with customers. When working with teams, the first challenge is to get people to believe they can achieve breakthrough improvements, such as reducing a 30 day loan cycle to 2 days. Teams who experience this workshop prove they can do it themselves. Two or three 20 minute rounds represent a production day at the Move It! company. Between the rounds, participants apply techniques and come up with solutions to implement. As in real life, some solutions work and some don't. The importance of thorough analysis proves itself again and again. By the end, teams have amazing improvements in cycle time and usually zero defects. Everyone is excited by the major leaps forward teams have made.
This 1 day training can be ordered separately, e.g. as part of a champion or awareness training. 11
IBM GBS | Lean Sigma Training in detail | 12-Aug-08
© Copyright IBM Corporation 2008
IBM Global Business Services
IBM is able to provide Black Belt and Green Belt trainings with two different statistic tools: Minitab and SigmaXL Avg days Order to delivery time LSL = 45
Target = 50
USL = 55
Count = 100,00 Mean = 49,02 Stdev (Overall) = 5,98 USL = 55,00 Target = 50,00 LSL = 45,00
20
15 Capability Indices using Overall Standard Deviation Pp = 0,28 Ppu = 0,33 Ppl = 0,22 Ppk = 0,22 Cpm = 0,28
10
Expected Overall Performance ppm > USL = 158576,0 ppm < LSL = 250645,0 ppm Total = 409221,0 % > USL = 15,86% % < LSL = 25,06% % Total = 40,92%
5
Process Capability of Avg days Order to delivery time
SigmaXLChartSheet
P otential (Within) C apability Avg days Order to delivery time Cp 0,30 C PL 0,24 C PU 0,36 C pk 0,24 C C pk 0,30
65,9
63,6
61,3
59,0
56,7
54,4
52,1
Within Ov erall
49,8
42,9
40,6
38,3
36,0
0
47,5
USL 45,2
LSL P rocess Data LS L 45,00000 Target * USL 55,00000 Sample M ean 49,02000 Sample N 100 StDev (Within) 5,48034 StDev (O v erall) 5,99316
Actual (Empirical) Performance % > USL = 16,00% % < LSL = 24,00% % Total = 40,00%
Capability analysis using SigmaXL
O v erall C apability Pp PPL PPU P pk C pm
35 O bserv ed P erformance P P M < LS L 240000,00 P P M > U SL 160000,00 P P M Total 400000,00
E xp. PPM PPM PPM
40
45
Within P erformance < LSL 231617,08 > U S L 137598,14 Total 369215,22
50
55
60
0,28 0,22 0,33 0,22 *
65
E xp. O v erall P erformance P P M < LSL 251185,07 P P M > U S L 159186,98 P P M Total 410372,05
Capability analysis using Minitab
Minitab is first choice for most of the Black Belts. But SigmaXL is less complex, Excel bases and very price competitive (
