Year

0
1
2
3
4
5

Assumed
Assumed
Outflow
Inflow
200000000
2000000
55000000
2000000
55000000
2000000
55000000
2000000
55000000
2000000
55000000
210000000 275000000
NPV

Netflow
53000000
53000000
53000000
53000000
53000000
191,053,138.72
8,946,861.28

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Content
About Benchmark Sig Sigma
Benchmark Six Sigma Certification

DMAIC
DEFINE
Lean Six Sigma
Lean Six Sigma
Organisational Change Management
John Kotter
Resistance
Stakholder Analysis
Roles & Responsibility
STEP 1

STEP2

STEP 3
Define Phase Summary

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MEASURE

STEP 4

STEP 5

STEP 5

STEP 6

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1 ANALYSIS
1 STEP 7
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2 STEP 8
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STEP 9
IMPROVE
STEP 10

STEP 10

STEP 11

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2 CONTROL
2 STEP 13

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Sub Content
Definition
Press Release
Pre Requisite
Roadmap
Overview
Roadmap
Success Fators
Reasons for failure
8 Step change
Type
How to Deal

Peoject Identification Mehtods

VOC
CTQ
Categories of Performance Metrics
Output Measures
Balanced Scorecard
Replication Opportunity
Benchmarking
Language processing tools
Affinity Diagram
Affinity diagram solution
Goal Means Diagram
Project Y
Problem definition Tree example
Rules of making splits
Rules of Decision Tree
Qualty Function Deployment (QFD)
Choice of CTQ and Project Y
The Big Picture
Primary Metric & Secondary metrics
Screening for DMAIC
Priortization Matrix
Project Charter
Prject Scoping Tool
Calculation of Financial Benefits
ROI / IRR / NPV
Team Selection
Time Management
SIPOC
Toll Gate Reviews

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9
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42-44
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59
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62
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64
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68-69
70

Overview
Roadmap
What & Where to Measure
Process and Inout Measures
Performance standards of Y
Operational Definition
Performance Standard Matrix
Validate Measurement system for Y
Measurement System Analysis (MSA)
Types of Measurement error
Precision vs Accuracy
Stability vs Lineraity
Discrimation
Calibaration & Traceability
Repetability & Reproducibity
Criteria for acceptance
MSA Checklist
R & R Study
Gage study for continuous R&R
Continuous Gage R&R Approach
Fundamental Properties
Gage R&R Example
Calculations Gage R&R Nos
Attribute Measurement System
Attribute agreement analysis - Procedure
Gage study for discrete data
Attribute R&R Example
Attrbute Agreement Result Analysis
Recommendations from Attribute R&R
Exercise Attribute R7R
Logical Validation
Measure Current Performance & Gap
Sigma Level
Control & Specification limits
Short term vs Long Term Performance
Process Dynamics
Subgrouping
Process Performance
Establish Baseline
Process Dynamics
Sigma level measurement
Definition of Z Bench
Calculating Sigma level
Short term & Long Term Performance
Short term & Long Term Performance
Sigma level for continuous data
Zlt or Zst
Mean and Target

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Sigma level for attribute data

Yield Concepts
Yield Definitions
Yield Calculation
Sigma level for Yield
Sigma level / DMPO Table
Calculating Sigma level
Yield to Sigma Level
Probability distribution
Central Limit Theorum
Process Capability Index
Proces Capability Indices
Capability Index - CP
CP & Cpk
Cpu, Cpl, Cpk
Definition of Cpk, Ppk, Cp
Process Capability usimng Minitab
Sigma level for normal data
Z entitlement for normal data
Z goal
Zent, Zgoal & Zbench data for non normal data
Box Cox transformation
Box Cox transformation inputs
Capability Analysis : Box Cox
Non Normal Capability Analysis
Non Normal Capability Outputs
Probability distribution
Common Probablity Distribution
Process capability for defectives : Binomial
Binomial capbility Analysis Inputs
Binomial capbility Analysis Outputs
Measure Phase Toll gate review
Measure Phase Review
ROADMAP
List all Potential Xs
Sources of Variation
Key Process Input Variables
Affinity Diagram
Fishbone / C&E / Ishikawa Diagram
Process map Analysis
VA/NVA (LEAN)
VA NVA Analysis Process
Risk Analysis
FMEA - Operation Definition
What is Failure Mode
Cause & Effect
PFMEA
Developing PFMEA

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PFMEA Template
Body of PFMEA
Definitions
Severity
Occurrence
Detection
Risk Priority Number
FMEA Concept
Action Plan
Notes on reduction in RPN Numbers
FMEA Excercisse - Manhattan Cabs
RPN Reduction
Pareto Application
Pareto Analysis
Pareto Chart
VOC : Critical to Satisfaction
What do customers want?
Customers crucial to business
Plan for VOC Data
Step 1 - Identify information needed
Step 2 - Develop Research Plan
Step 2 - Develop Questionaire
Step 3 - Collect the VOC Data
Step 4 - Transalate VOC to CCR
Step 4 - Critical Customer Requirements
Managing Teams
Addressing Resistance
Continous Data
Normal Distrbution
Standard Normal Curve
Normal Distribution Example
DMPO & the normal curve
DMPO & Z Value examples
Identify Critical Xs
Hypothesis Testing Problem Flow
What is Hypothesis
Formulating the right hypothesis
Hypothesis Testing Types
Hypothesis Testing : Acceptance Criteria
Types of Error
Hypothesis Testing : Acceptance Criteria
Hypothesis Testing : Choosing Alpha Level
Choosing Alpha Level Example
Hypothesis Testing : Represnting Alpha, Beta
Data Analysis Tool
Hypothesis Testing Procedure
Y continous, X Discrete
1 sample Z Test Example

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1 sample Z Test : Normality Test

Selection of Right Analysis Tool
1 Sample Z Test Exercise
1 Sample Z Test : Sample Size
1 Sample Z Test Sample Size Examples
Selection of Right Analysis Tool
1 Sample T Test
1 Sample T Test : Exercise
Normality Test for Scores
1 Sample Sign Test
2 Sample T Test
Test for Normality
Selection of Right Analysis Tool
Test for Equal Variances Input
Test for Equal Variances Output
2 Sample T Test
2 Sample T Test Inputs
2 Sample T Test Outputs
2 Sample T Test : Exercise
2 Sample T Test Sample Size Inouts
2 Sample T Test Sample Size Outputs
Paired Test
2 Sample T Test or Paired T Test
2 Sample T Test Assumptions Check
Mean - Whitney Test Output
Normality Assumption
Check for Equal Variances
Case 1 : 2 Sample T Test
Case 2 : 2 Paired T Test
Statistical vs Practical Signifcance
Ananlysis of Variance (ANOVA)
One Qay Anova Example
Normality Test
Check for Equal Variances
Selection of Right Analysis Tool
One Way Annova Exercise
One Way Anova Outputs
Visualizing within & between
Non Parametric Equvalent to ANOVA
Mood's Median vs Krushal Wallis
Mood's Median Test
Kruskal Wallis Test
Data Analysis Tool
Analysis for Y Discrete, X Discrete
1 proportion Test Example
1 proportion test - Solution
1 proportion Test Exercise
Sample Size for 1 proportion Test Exercise

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2 Proportions Test
2 Proportions Test Example
2 Proportions Test Solution
Chi-Square Test
Test for Homogenity Example
Chi-Square Test Solution
Chi-Square Test Outputs
Data Analysis Tool
Analysis for Y Continuous, X Contiuous
Scatter Diagrams
Scatter Diagrams Interpretation
Correlation Analysis
Regression Analysis
Regression Terms
Correlation Analysis Example
Correlation Coefficient
Regression Analysis Example
What is R Squared
Regression Analysis Inputs
Regression Analysis Outputs
Residual Analysis
Regression : Graph Analysis
Regression Analysis Equation
Regression Analysis : -R-Sq Values
Regression Analysis : P Value
Data Analysis Tool
Analysis for Y Discrete, X Continuous
Binary Logistic Regression + Example
Binary Logistic Regression Inputs
Binary Logistic Regression Outputs
Scatter Plot for Event Probabilities
Sufficiency of Critical Xs
Analyse Tollgate checklist
ROADMAP
Generate Alternative Solutions
Brainstorming
Creative Thinking : Six Thinking Hats
How to Use Six Thinking Hats
Types of Benchmarking
Process Benchmarking
Evaluating Solutions
Pugh Matrix
Delphi Technique
Multi Voting and Nominal Group Technique
Select and Optimize the best Solution - DOE
Design of Experiments (DOE)
DOE Terms
Types of Experiments

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DOE : Types
DOE : Phases
Fctors and Lack of use of DOE
DOE : Steps
DOE : Full factorial design
Fractional Factorial Designs
Full Factorial Design
DOE : Characterstics
Mains and Interaction Effect
Mains Effect
Interaction Effect
Exercise
Creation of a Designed Experiment
Create Design Output
Number of Test Runs required
Power & Sample Size
Blocking
Define a Custom Design
DOE Example
DOE Inputs
Check Model Assumptions
Full Factorial Results Analysis
DOE Analysis - Session Window
DOE Model Reduction
Finall Reduced Model
DOE - Main Effects Plot
DOE - Interaction Effects Plot
DOE - Interaction Effects
DOE - Cube Plot
Contour & Surface Plots
Contour / Surface Plots
DOE - Contour Plot
DOE - Practical Example
Exercise - DOE Analysis
Fractional Factorial Design
Fractional Factorial Design : Terms
Fractional Factorial Design
Creating Fractional Factorial Design
Fractional Factorial Design Outputs
Fractional Factorial Design
Randomised Blocks & Latin Square
Pilot, Measurement & Validate the Solution
Pre-Pilot and Post Pilot
Pilot Completion Review
Implementation Review
Improve Tollgate Basic Checklist
ROADMAP
Implement Control System for Critical Xs

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Measure System Re-Analysis

Statistical Process Control (SPC)
Control Charts
Control Charts or SPC ro SQC
Control Charts
Rational Sub Grouping
Control Chart - Types
Control Chart : I -MR
I-MR Chart : Check Normality
I-MR Chart : Control Charts
I-MR Chart : Moving Range Chart
I-MR Individual Chart
Control Chart : X-bar Chart
X Bar R Chart Example
Control Chart : X-bar R Chart
Control Chart : X-bar
Control Chart : X bar R
Control Chart : R Chart
Control Chart : X-bar R Chart
Control Chart : X bar S Chart
Control Chart Constants
X bar S vs X-bar Chart
Control Charts : Attribute Data
Control Charts : P
Control Charts : P Outputs
Control Charts : P
Control Charts : NP
Control Charts : C
Control Charts : U
Control Charts : Out of control points
Control Plan
Control Plan Example
Standards & Procedures
Document Solution and Benefits
Validation of Financial Savings
Training & Lesson Leadrned
Transfer to Project Owner, Project Closure
Project Sign off sheet
Control Tollgate Checklist

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Detail

***

Crossed designs
Use Annova for accuracy
Ten to one rule

Cohens kappa

If conducting an MSA is not possible

Objective is to evaluate current performance of Y and basline it for comparison post improvement

Common cause & special cause variation

Common cause & special cause variation

Convert the following to Sigma level to get the Z Bench(DPMO LSL + DPMO USL)
Zlt and Zst
Diff between continous and attribute data
Overall standard deviation and Within Standard deviation

With Defects, Yield and Defectives

For continuous and discrete data
CLT /
Details of CP and CPK
Cp, Cpk, Pp, Ppk - Meaning and Formula
SW / PW
Calculation

Box Cox transaformation

Not discussed
Not discussed
Not discussed
Not discussed
Not discussed
Not discussed
PD for Probability distribution
Not discussed
Not discussed
Not discussed

Y = F(X) = X1 + X2 + X3 + .
KPOV = F (KPIV)
Cause & Effect
***

Process step / Product function, Potential failure mode, Potential effect of the failure, Potential Caus

Exercise

Exercise

Exercise