DPA Consulting Services
Lean Six Sigma Course Offerings
Besides offering hands-on consulting support for Lean Transformation, Daniel Penn Associates offers
a full spectrum of courses in Lean and Six Sigma, addressing executives and senior management, managers
and supervisors, and operations personnel and support staff. Courses are offered on-site, at your premises,
and can be tailored to your specific needs and requirements. We offer both specific courses for immediate
needs and certification courses that lead to professional recognition within Lean (Society of Manufacturing
Engineers) and Six Sigma (American Society for Quality).
Our instructors are Lean Masters, Master Senseis, and Black and Master Black Belts with 20 or more
years experience teaching, facilitating and mentoring to both industry and government.
Lean Six Sigma Courses
Lean Six Sigma General Overview
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Audience: |
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Anyone |
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Duration: |
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One day |
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Topics: |
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Know what Lean Six Sigma is, why it’s needed, what it can do. |
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Prerequisites: |
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None. |
Lean Six Sigma for Executives
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Audience: |
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Executives, Directors, Commanders |
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Duration: |
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One-day |
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Topics: |
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Know what Lean Six Sigma is, why it’s needed, what it can do.
Understand how Lean Six Sigma enhances a business strategy.
Know the strategy and phasing of the Lean Six Sigma methodology.
Become familiar with the Lean Six Sigma tools and their application.
Understand the issues of variability and their impact on decision making.
Know how to find and remove barriers and constraints.
Understand a knowledge-based pull system.
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Prerequisites: |
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None. |
Lean Six Sigma for Champions
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Audience: |
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Senior leaders that will champion a Lean Six Sigma effort.
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Duration: |
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Two-days |
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Topics: |
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All topics in the Lean Six Sigma for Executives course.
Know the roles and responsibilities of a Lean Six Sigma Champion.
Become aligned with the organization’s rollout plan.
Support an effective, accelerated implementation of Lean Six Sigma.
Know how to select and prioritize projects.
Be a strong proponent of Lean Six Sigma to help drive business results.
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Prerequisites: |
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None. |
Lean Six Sigma for Managers
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Audience: |
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Managers and Supervisors with decision authority to apply Lean Six
Sigma. |
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Duration: |
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Five-days |
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Topics: |
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Know what Lean Six Sigma is, why it’s needed, what it can do.
Know the strategy and phasing of the Lean Six Sigma methodology.
Become familiar with the Lean Six Sigma tools and their application.
Understand the issues of variability and their impact on decision making.
Know how to find and remove barriers and constraints.
Understand a knowledge-based pull system.
Understand the eleven key elements of a fully integrated Lean Six Sigma business improvement effort.
Learn how these key elements are deployed during the Initialization, Execution and Assessment phases.
Understand ‘best practices’ and customize a deployment approach that best meets your requirements.
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Prerequisites: |
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None. |
Transactional Design (TDFSS)
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Audience: |
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Green Belts, Black Belts |
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Duration: |
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One day |
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Topics: |
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Introduction to Transactional Design for Lean Six Sigma.
Understand project management, voice of the customer (VOC), and keeping score.
Three level process maps with control systems.
Pugh concept selection and lean concepts.
Failure mode and effects analysis (FMEA).
Monte Carlo methods and process simulation.
Process capability prediction and test and validate.
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Prerequisites: |
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None. |
Lean Courses
Lean Manufacturing
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Audience: |
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Managers, supervisors, facilitators |
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Duration: |
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One day |
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Topics: |
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Understand the terms, terminology, and benefits of Lean Manufacturing.
Conduct value stream maps of the current state.
Identify the potentials for reduced waste and improved flow.
Develop a future state map.
Participate in the development of a site-specific lean implementation road map.
Avoid the common pitfalls encountered during lean implementation.
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Prerequisites: |
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None. |
Lean Enterprise Introduction
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Audience: |
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Managers, supervisors, facilitators |
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Duration: |
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Two days |
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Topics: |
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Lean Overview
Lean Enterprise methods (Pull Production, Supply Chain Management, Kaizen, Visual Workplace, TPM, Cellular Production, JIT, Quick Change Over) and tools (Poka Yoke, SMED, TOC, Kanban, Andon).
Value stream mapping and analysis
Theory of Contraints (TOC) – eliminating constraints and bottlenecks.
Inspection, In-Station Process Control and Statistical Process Control (SPC).
Robust Design and Design of Experiments (DOE).
Seven sources of waste and methods to eliminate waste.
Identify and eliminate waste in a small project.
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Prerequisites: |
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None. |
Lean Practices
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Audience: |
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Anyone |
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Duration: |
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Five days |
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Topics: |
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Introduction to Lean and the Seven Wastes.
Implementing TPM, 5S, and visual control techniques.
JIT and Kanbans.
Quick change-overs and error proofing.
Action workouts.
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Prerequisites: |
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None. |
The 6S's: Workplace Organization
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Audience: |
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Managers, supervisors, facilitators, operations personnel |
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Duration: |
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One day |
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Topics: |
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Understand each of the six S’s and how each “S” builds upon the previous “S.”
Apply the 6S’s to the work area.
Develop (or participate in the development of) a 6S implementation road map.
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Prerequisites: |
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None. |
Six Sigma Courses
Six Sigma Yellow Belt Training
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Audience: |
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Anyone |
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Duration: |
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One day |
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Topics: |
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Understand the Six Sigma culture.
Know and apply Six Sigma concepts to improving the bottom line.
Understand and apply the DMAIC phasing and control points to a project.
Appreciate the need and use of statistics in process improvement.
Describe a process numerically.
Use and apply basic graphical tools and charting techniques.
Understand the relationship between variation and the cost of poor quality.
Conduct a Measurement System Analysis (MSA) to determine the integrity of data.
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Prerequisites: |
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None. |
Six Sigma Green Belt Training
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Audience: |
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Students desiring a Green Belt certification. |
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Duration: |
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Five days |
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Topics: |
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Module 1 - Lean Six Sigma... The Journey Begins
Module 2 - What is Lean Six Sigma?
Module 3 - Introduction to Lean and Seven Wastes
Module 4 - Define Phase: Project Definition & Waste Management. Teamwork, Understanding Change, and Voice of the Customer
Module 5 - The Role of Statistics in Process Improvement
Module 6 - Making Sense Out of Data Using Graphical & Measurement Tools
Module 7 - Measurement Systems Analysis
Module 8 - Sampling Distributions and Confidence Intervals
Module 9 - Drawing Conclusions When Comparing Data Sets
Module 10 - Process Control and Process Capability
Module 11 - Implementing TPM, 5S, and Visual Control Techniques
Module 12 - JIT and Kanban’s
Module 13 - Quick-Changeovers and Error Proofing
Module 14 - Action Workouts
Module 15 - Introduction to Regression Analysis and Modeling
Module 16 - The Control Phase (Realizing and Holding the Gains)
Module 17 - References, Glossary of Terms, and Course Evaluation Forms
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Prerequisites: |
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Six Sigma Yellow Belt. |
Six Sigma Black Belt Training
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Audience: |
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Green Belts desiring a Black Belt certification. |
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Duration: |
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Eighteen Days. |
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Topics: |
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Module 1 - Lean Six Sigma... The Journey Begins
Module 2 - What is Lean Six Sigma?
Module 3 - Define Phase: Project Definition, Teamwork, and Voice of the Customer
Module 4 - The Role of Statistics in Process Improvement
Module 5 - Making Sense Out of Data Using Graphical & Measurement Tools
Module 6 - Measurement System Analysis
Module 7 - Standard Work Analysis
Module 8 - Improving the Flow
Module 9 - Drawing Conclusions from Sampled Data
Module 10 - The Control Phase (Realizing and Holding the Gains)
Module 11 - Understanding Data Distributions and Their Applications
Module 12 - Sampling Distributions and Confidence Intervals
Module 13 - Introduction to Regression Analysis and DOE
Module 14 - Foundations of Design of Experiments
Module 15 - Introduction to Design and Analysis
Module 16 - Rules of Thumb
Module 17 - Using Regression to Analyze DOE Data
Module 18 - Three-Level Designs
Module 19 - Extending DOE Concepts to Include Multiple Response Optimization
Module 20 - Historical Data Analysis
Module 21 - Putting It All Together: Refocusing on the Big Picture
Module 22 - Next Steps ... the Journey Continues
Module 23 - Special Topics
Module 24 - References, Glossary of Terms, and Course Evaluation Forms
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Prerequisites: |
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Six Sigma Green Belt certification. |
Six Sigma Master Black Belt Training
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Audience: |
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Black Belts desiring a Master Black Belt certification. |
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Duration: |
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Ten days |
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Topics: |
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Module 1 - Six Sigma Definitions & Terminology.
Module 2 - Define (IDOV vs. DMAIC, VOC, decision tools, project selection).
Module 3 - Measure (analysis, goodness of fit, transformations to normality).
Module 4 - Analyze (t-tests, ANOVA, historical data analysis, multiple regression, regression diagnostics, cross-validation).
Module 5 - Analyze (orthogonality, OFAT, blocking, repetitions vs. replications, variable input, screening vs. modeling, sequential CCDs, attribute responses).
Module 6 - Improve (multiple response optimization, high throughput testing (HTT), analysis using simulation).
Module 7 - Control (topics in SPC, sample size, minimizing Type I & Type II errors, short-run SPC).
Module 8 - Introduction to Design for Six Sigma (DFSS).
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Prerequisites: |
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Six Sigma Black Belt certification. |
Statistical Process Control (SPC)
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Audience: |
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Green Belts, Black Belts, Engineers, Supervisors. |
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Duration: |
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Five days |
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Topics: |
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Module 1 - SPC Basics.
Module 2 - Data Description and Display.
Module 3 - Probability Distributions.
Module 4 - Statistical Inferences.
Module 5 - Process Variability.
Module 6 - Control Charts for Variables.
Module 7 - Control Charts for Attributes.
Module 8 - Other Control Charts.
Module 9 - Measurement System Analysis.
Module 10 - Acceptance Sampling.
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Prerequisites: |
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Six Sigma Green Belt or equivalent quality course / experience. |
Advanced Statistics for Six Sigma Black Belts
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Audience: |
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Six Sigma Black Belts |
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Duration: |
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Five days |
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Topics: |
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Module 1 - Overview of data mining.
Module 2 - Data preparation, visualization, dictionaries.
Module 3 - Modeling (dimensionality, notation and terms, bias-variance tradeoffs, error functions).
Module 4 - Traditional models (linear regression, logistic regression, discriminant, analysis, nearest neighbors, clustering algorithms).
Module 5 - Modern models (classification and regression trees, neural networks, bump hunting, association rules, evaluating and combining models).
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Prerequisites: |
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Six Sigma Black Belt certification. |
Six Sigma Train the Trainer
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Audience: |
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Green, Black and Master Black Belts |
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Duration: |
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Ten days |
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Topics: |
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Day 1
Six Sigma Master Black Belt, Black
Belt, Green Belt Roles
Training Philosophy
Teaching Basics
Physical / Logistical Requirements
Evaluating the Course
Classroom Observations
Days 2-10
Review Each Module
Review Take Aways
Review Objectives
Practice Teaching
Observation / Critique / Feedback
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Prerequisites: |
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Appropriate Six Sigma certificate. |
Design for Six Sigma (DFSS) for Managers
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Audience: |
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Managers, Supervisors, Leaders |
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Duration: |
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Two Days |
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Topics: |
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Know what Design for Six Sigma (DFSS) is and how it differs from Lean Six Sigma.
Understand the four phases: Identify, Design, Optimize, Validate (IDOV).
Know the leadership responsibility in deploying DFSS.
Understand the benefits and vision of DFSS.
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Prerequisites: |
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None. |
Other Related Courses
Design of Experiments (DOE)
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Audience: |
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Black Belts, Managers, Engineers. |
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Duration: |
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One day |
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Topics: |
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Foundations and overview of DOE.
Introduction to Design and Analysis.
Rules of thumb.
Using regression to analyze data.
Two-level design summary.
Three-level design summary.
Taguchi, variance reduction methods, robust designs, and multivariate charts.
Randomization and multiple response optimization.
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Prerequisites: |
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Green Belts, Black Belts. |
Introduction to Reliability Testing & Analysis
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Audience: |
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Black Belts, Managers, Engineers. |
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Duration: |
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Five Days |
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Topics: |
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Basic statistical concepts (confidence intervals, hypothesis testing).
Graphical tools (dot plot, histogram, box plot, end count test).
Reliability concepts (reliability function, hazard function, bathtub curve, censoring).
Common Reliability Distributions (exponential, Weibull, normal, lognormal).
Non-parametric reliability (Kaplan-Meier Estimates, comparing survival curves).
Probability plotting.
Estimation (least squares, maximum likelihood, failure times, probability of failure).
System failure (series, parallel, R out of N, competing risk model, multiple failure modes).
Planning reliability tests and sample size.
Accelerated life testing (linear, equal linear, Arrhenius acceleration).
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Prerequisites: |
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None. |
Root Cause Analysis (RCA)
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Audience: |
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Green Belts, Black Belts, Managers, Engineers. |
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Duration: |
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One day |
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Topics: |
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Understanding why root causes are important.
Identifying and defining problems.
Analyzing change and identifying variability.
Defining and finding the golden nugget (3 P’s and Rule of Ten).
Analyzing data for root causes.
Identifying contributing events.
Simple root cause analysis TREE.
Five W’s technique of root cause analysis.
Mistake proofing.
Guidelines on conducting individual analysis.
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Prerequisites: |
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None. |
Evolving Quality Systems - ISO
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Audience: |
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Engineers, manufacturing and quality professionals |
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Duration: |
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One day |
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Topics: |
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Understanding and determining evolving quality requirements such as ISO 9001:2000 (including AS, QS, TS and other standards).
Increasing awareness for the enterprises quality management system.
Tools for assessing your quality system and gap analysis.
Improve corrective action planning and reference resources.
Selecting a registrar.
Performing Internal audits.
Creating a quality system continuous improvement plan.
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Prerequisites: |
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None. |
DPA. . . Services
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