Lean Six Sigma Course: Lean Manufacturing with Poka Yoke

Six Sigma is the most widely used and widely adopted method to raise quality. It isn't always understood as DMAIC. DMAIC which refers to a data-driven process that requires the following steps: Define, Measure, Analyze, Improve, and Control

A Lean Six Sigma Training Course

Six Sigma is the most widely used and widely adopted method to raise quality. It isn't always understood as DMAIC. DMAIC which refers to a data-driven process that requires the following steps: Define, Measure, Analyze, Improve, and Control. 

Six Sigma is an organization wide strategy and methodology for process improvement that focuses on a continual improvement culture. Six Sigma is generally driven by data. It can be used to improve the efficiency and effectiveness of any business or non-profit process.


A Lean Management Course

Lean management is a philosophy that focuses on identifying and eliminating waste in production processes and activities. It strives to achieve more with less. It also aims at creating products and services that are of high value and quality. This includes producing the desired results at a lower cost.  


Manufacturing for Lean Six Sigma

The manufacturing for Lean Six Sigma course teaches participants the basics of lean manufacturing. It helps them understanding how to apply lean concepts within a manufacturing environment. The course also covers some of the basic statistical principles used in Six Sigma projects.


A Poka Yoke Training Course

Poka Yoke is a Japanese term that means "mistake proofing." The idea is to design products and processes so that they are easy to use and difficult to break.
Poka Yoke training course has been designed by the POKA YOKE Support Center. POKA YOKE Support Center is a nonprofit organization that provides free online training in Poka Yoke techniques. The course was created by the Japanese Industrial Engineering Society (JIES). It has been translated into English, French, German, Chinese, Korean and Spanish.
The course teaches how to design simple systems with few parts that can be assembled without any tools. It also teaches how to design safety features for machines or devices so they will stop automatically if something goes wrong. 

A Value Stream Mapping Training Course

Value Stream Mapping is a technique for analyzing the flow of materials, information and money through a system.
Value stream mapping is a technique for analyzing the flow of materials, information and money through a system. It can be applied to any process that involves more than one step, such as manufacturing, distribution or service delivery.
Value stream map is used to identify and eliminate waste in the process. It is applied by identifying what steps are necessary to produce the desired output.
The objective of value stream mapping is to find ways to reduce lead time. It also aims at improving productivity by reducing work-in-process inventory.


Targeted Audience For The Lean Six Sigma Training

  • Quality Managers & Quality Engineers.

  • Operation Managers & Operation Engineers.

  • Quality Team Members.

  • Quality Management System Auditors.

  • People involved with quality management in their companies.

  • Quality Assurance /Quality Control Specialists.

  • Quality analysts.

  • Supply Chain Experts.


Targeted Organizational Departments for The Lean Six Sigma Training

  • Top Management.

  • Quality Department.

  • Operation Department.


Targeted Industries for The Lean Six Sigma Training

  • Lean is a methodology that is effective in every single sector. whether it is IT, manufacturing, military, or health care.

Learning Outcomes for The Lean Six Sigma Training

By the End of This Course Participants Will Be Able to:

  • Master Lean Management and Lean Manufacturing Techniques.

  • Learn numerous techniques to recognize and eliminate inefficiencies from your work surrounding.

  • Recognize and mitigate the 7+1 forms of waste.

  • Apply The 5S training to improve the layout.

  • Apply OEE Overall Equipment Effectiveness to quantify waste.

  • Apply Little’s Law to understand waiting lines.

  • Apply Lean visuals and Master the Value Stream Mapping.

  • Draw Value Stream Maps and visualize supply chain problems.

  • Get A properK ANBAN training to streamline communication & understand the Kanban method.

  • Mitigate bottlenecks and speed up your process.

  • Learn the cycle time optimization to reduce costs.

  • Draw and use the QFD House Of Quality to design products and services

  • Move from Push to Pull production to reduce waste.

  • Integrate a Just In Time JIT Manufacturing into production system and minimize inventory.

  • Apply production leveling (Heijunka) and respond to customers faster

  • Apply Poka Yoke and make your products and services mistake-proof.

  • Apply SMED Single Minute Exchange of Die to switch production faster.

  • Apply Jidoka principle to quickly find abnormalities.

  • Improve The Supply Chain Including Material and Information Flow.


Course Toolbox

  • Reading List.

  • Course Material.

  • House of Quality Templet.

  • A Group of Exercises.

  • Many Case Studies.


Course Agenda:


Day (1) Introduction to Lean & Six Sigma

  • Toyota Production System.

  • Process and lead time.

  • Value Adding Vs (Non) value adding activities.

  • How Lean and Six Sigma are related?

  • What is Kaizen?

  • Quality Function Deployment (QDF).

  • Overall Equipment Effectiveness (OEE).

  • Apply The JIT just in time training.

  • Apply The Jidoka method.

  • What is Heijunka & Heijunka box.


Day (2) Identifying and Reducing Waste

  • The 7+1 types of waste.

  • Reducing waste of defects (Poka Yoke, Standardized work).

  • Reducing the waste of over processing.

  • Reducing the waste of transport.

  • Reducing the waste of motion.

  • Reducing the waste of waiting.

  • Reducing the waste of inventory.

  • Reducing the waste of over production.

  • Reducing the 8th form of waste.


Day (3) Kanban Training, Visual Work floor, & 5S Training

  • What is Kanban?

  • What is Visual Visual Work floor ?

  • What is 5S.

  • Value Stream Mapping (VSM).


Day (4) Mistake Proofing and Poka Yoke

  • What is the ZQC System?

  • Common Causes of Defects.

  • How is ZQC different from Traditional Quality Improvements?

  • The Four Elements of ZQC System.

  • Different approaches to inspection.


Day (5) Mistake Proofing and Poka Yoke

  • How does Poka Yoke Work?

  • Fixed Value Methods

  • Motion Step Methods.

  • Different types of Sensing Devices.

  • Examples of Poka Yoke.

  • Contact, Fixed Value and Motion Step Examples.


What Sets This Apart From The Other Logistics And Supply Chain Management Courses ?

Supply chain management involves the analysis of inventory levels, production and distribution of goods, transportation, warehousing and other activities. Supply chain management is very important in today’s world. Because there is a need to reduce lead time and minimize the cost of logistics. This course will teach participants a lot of techniques to thrive in Logistics And Supply Chain Management