Lean Six Sigma Green Belt Training: Summer 2013

May 20-June 17, 2013 via Distance Learning

• About the Course
• Who Should Attend
• Requirements
• Materials Provided
• Location/Distance Learning
• Course Outline
• Instructor
• Fees and Registration

About the Course

Some of today's most respected companies—including GE, Motorola, Allied Signal, and Sun Microsystems—have used Lean Six Sigma to improve their organizations. Join the ranks of these successful corporations and let Lean Six Sigma work for you.

Lean Six Sigma is a combined process-improvement methodology that accelerates processes, increases efficiency, and reduces or eliminates variation. Competition for the same customers is increasing throughout the corporate world, putting company profits on the line; customer expectations are changing rapidly as the rate of information increases; and costs are escalating. Now more than ever, achieving process excellence is essential.

Our Lean Six Sigma program gives you valuable business tools to achieve process excellence and help your team:

• Redesign flow to better account for customer and supplier variability
• Analyze the root causes of process or system problems
• Make informed decisions about cost-benefit of a company project
• Capture meaningful metrics to help know and grow your business
• Experiment to determine best practices to deliver quality, every time

This offering is a pre-recorded rebroadcast of our Winter 2013 Lean Six Sigma Green Belt (LSSGB) program offered by the Systems Science and Industrial Engineering (SSIE) Department at the Thomas J. Watson School of Engineering and Applied Science at Binghamton University and the Binghamton University IIE Student Chapter.   This training is also highly recommended for anyone who wishes to continue on with the Lean Six Sigma Black Belt training being offered in August 2013.

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Who Should Attend

This course is open to all current BU students as well as alumni, non-BU students, and members of industry, non-profit and government agencies.

This short course is designed for students or industry professionals that have some coursework background in probability and statistics and/or quality control*.  The training consists of eleven 90-minute pre-recorded lectures and includes soft copies of the slides.  In order to be a certified green belt, the participant will be expected to pass a take-home examination within a month of the start of the course.  Participants will have support via access to virtual office hours and email contacts to the professor and teaching assistant during the month.  A Lean Six Sigma Green Belt certificate will be provided to those who successfully complete the course.

*Students or individuals who do not have current knowledge/education in the probability and statistics and/or quality control may enroll in this course; however, they are also required to attend (at an additional cost) the prerequisite statistics day of instruction which is comprised of four addition 90-minute pre-recorded lectures.

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Requirements

• Knowledge/education in probability & statistics and/or quality control.  BU students: Some examples of courses that fulfill this pre-requisute include ISE 261, ISE 362, SSIE 505. (*Those who do not have current knowledge/education in the probability and statistics and/or quality control may enroll in this course, however, they are also required to view the prerequisite statistics day of instruction (at an additional cost) which is comprised of four addition 90-minute pre-recorded lectures.)
• Computer with a high speed internet connection and Microsoft Excel (Required for Day 2 and 3).  A limited number of laptops are available through our Educational Communications Center (EdComm) through the Audio-Visual services in Lecture Hall B-60. There is no cost to use these laptops for BU students. Information regarding this policy can be found at http://www.ecc.binghamton.edu/av/avpolicy.html.
• It is recommended that participants download a trial version (free for 30 days) of the Minitab software (for statistical analysis - http://www.minitab.com) on or a day before the start of the training program.  Minitab is available for free for all BU students (https://ssl.binghamton.edu/). 
• In order to utilize the Collaborate tool for virtual office hours, your computer should also have an updated version of JAVA (http://java.com/en/download/index.jsp)

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Materials Provided

Your fees cover:

• Instruction via pre-recorded lectures
• Soft copies of slides.
• Support via virtual office hours and email with the instructor and teaching assistant.
• Grading of take-home exam
• Lean Six Sigma Green Belt Certificate of Completion

Location

This course will only be offered through distance learning.  In order to utilize distance learning, the student must have a computer with a High Speed Internet connection.

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COURSE OUTLINE:

Links to the pre-recorded sessions and slides will be sent out on Monday, May 20, 2013.  These links will be available for one month.  An open-book take-home exam will be distributed on Friday, May 24, 2013.  This comprehensive exam will be due by Monday, June 17 at 9am.  Notification of course completion will be by mid-August.

Prerequisite Statistics: Four 90-minute lectures

* For those who do not have prerequisite coursework in statistics. 

• Session 1 - Course Introduction, Course Outline, Fundamental of Problem Solving, Introduction to Statistics, Sampling Process, Introduction to Minitab
• Session 2 - Basic Statistics: Measures of Location, Measures of Variability, Data Visualization, Coefficient of Variation, Dot Plot, Histogram, Steam And Leaf, Box Plot
• Session 3 - Basic Statistics: Random Distribution, Variables Types, T test, Z test, Statistical Tables, Confidence Intervals for Mean, Confidence Interval for Proportions, Confidence Interval for Standard Deviation
• Session 4 - Advanced Statistics: Compare Means, Compare Variances, Compare Proportions, Rejection Region, Fail to Reject, Type 1 error and Type 2 error, Power and Sample Size, P-value

Green Belt: Eleven 90-minute lectures

This program serves as a lean six sigma training course at the Green Belt level. The course aims to emphasize why the implementation of lean six sigma is vital to the continuous improvement in global industry. Several case studies and applications of lean six sigma concepts will be presented throughout the course. In addition, several educational games and group activities will be used throughout the course to illustrate many of the lean six sigma concepts. Focused topics include:

• Continuous process improvement (CPI) with emphasis on both lean and six sigma concepts and methodologies;
• Lean concepts and its applications, such as 5s, waste reduction, value stream mapping, and error proofing;
• DMAIC (Define, Measure, Analyze, Improve, and Control) to solve issues and transition CPI projects from one phase to another;
• Basic statistical analysis methods, tools, and control charts used to determine key relationships between inputs and outputs;
• The integration of both lean and six sigma for achieving data-driven process improvement results;
• and Team dynamics and leadership to provide effectively successful projects.

Course Outline:

• Session 1 - Six Sigma Tools: Basic Quality Concepts, Introduction to DMAIC Methodology, Brainstorming, Flow Charts, Force Field Analysis, Cause and Effect Diagrams, Nominal Group Techniques, Run Chart, Control Charts, Pareto Diagrams
• Session 2 - Process Definition: Process Flow Optimization, Forecasting Models, Process Capacity Expansion, Design Capacity, Continues Improvement, Kaizen
• Session 3 - Basic Lean: Just in Time, Total Quality, ISO, Six Sigma, Lean, PDSA Cycle, Statistical Process Control, The 7 Forms of Waste, Push and Pull, Kanban, Application of Lean in Healthcare
• Session 4- Lean Tools: Takt Time, Throughput Time, Standardized Work, Jidoka and Andon, Mistake Proofing, SMED, 5Ss, Kaizen Blitz Events, Spaghetti Diagram, Value Steam Map, SIPOC
• Session 5 - Six Sigma Project: Introduction to Six Sigma, Customer Requirements, Management Systems, Six Sigma Metrics, Critical to Quality, Process Capability, Stable Operations, Design for Six Sigma, Six Sigma DMAIC, Lean Six Sigma Project
• Session 6- Six Sigma Methodology: DMAIC Toolset, Project Management, System Value Stream Analysis, Project Selection, Decision Matrix, Multi Voting Project Scoping, Project Charter
• Session 7- Quality Project Tools: Check Sheet, Scatter Diagram, Affinity Diagram, Matrix Diagram, Arrow Diagram, Data Collection, Gauge R and R study
• Session 8- Quality Project Tools: R and R study Examples, Process Capability, Benchmarking, Correlation Analysis, Regression Analysis
• Session 9- Lean Six Sigma Project Case, Power and Sample Size, T test and Z test, CI for Mean and SD, Hypothesis Testing with Excel, A Sample Project Review
• Session 10- Design of Experiment: Design of Experiment, ANOVA, Failure Mode and Effects Analysis
• Session 11- QDF: House of Quality, Quality Function Deployment, X bar Chart, R Chart, P Charts, S Charts, Process Simulation, Simulation Example

An open-book take-home exam will be distributed on Friday, May 24, 2013.   The exam is long and comprehensive.  We recommend you allot 20-25 hours for completing the exam.

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Instructor

Dr. Mohammad T. Khasawneh 

• Associate Professor in Systems Science & Industrial Engineering Department
• Assistant Director for Health Systems, Watson Institute for Systems Excellence
• Director, Healthcare Systems Engineering Center
• Director, Human Factors and Ergonomics Laboratory
• Graduate Program Director, Executive Master of Science in Health Systems
• SUNY Chancellor's Award for Excellence in Teaching
• Ph.D., Industrial Engineering, Clemson University

Ms. Sura Khaled Al-Qudah (Teaching Assistant)

• Ph.D. candidate, Industrial and Systems Engineering, State University of New York at Binghamton
• Masters, Industrial and Systems Engineering, State University of New York at Binghamton
• BS, Electronics Engineering, Yarmouk University, Jordan
• Additional Experiences:
  • Research Assistant for projects with Howard Hughes Medical Instutute and Mayo Clinic
  • Electronics Engineer, Biomedical Center of Excellence at Yarmouk University
  • Engineering Intern, Royal Medical Services, Prince Rashed Military Hospital

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Fees and Registration

GREEN BELT course only (Eleven 90-minute lectures)

• STANDARD RATE: $600
• GOVERNMENT, NON PROFIT: $500
• CURRENT BU STUDENTS: $300

PREREQUISITE STATISTICS course + GREEN BELT course (Fifteen 90-minute lectures)

• STANDARD RATE: $750
• GOVERNMENT, NON-PROFIT: $600
• CURRENT BU STUDENTS: $400

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