The Define Phase creates the Project Charter that includes a high-level view of the process and defining the needs of the customers. The Define Phase inputs and outputs include:

• Review Project Charter
• Define Problem Statement and Goals
• Define the Voice of the Customer and Business
• Define the project Benefits
• Define and communicate Plan
• Define Team
• Develop the Schedule

The Measure Phase starts with establishing the current state (Baseline) of the process to determine the value of any process change. The team collects data to determine the starting point of the Baseline process and uses the data to look for clues to help identify root causes for waste or defects in the process. Detailed process maps are created as an output of the Measure Phase as a foundation step of the process. The inputs and outputs of the Measure Phase include:

• Define initial process map
• Identify Key Inputs and Metrics
• Develop Operational Definitions
• Validate Measurement System
• Develop Data Collection Plan
• Define the value of Baseline Data
• Determine Process Capability

The Analyze Phase reviews the collected data. Often different people collect different sets of data for review by the team. The team analysis of the data is processed to narrow down and verify the root causes of Waste and Defects. The team conducts Time Analysis, Value Added Analysis, and Value Stream Mapping to help determine where Waste can be removed from the process. Inputs and outputs of this phase include:

• Identify Potential Root Causes
• Reduce List of Potential Root Causes
• Confirm Root Causes to Output Relationship
• Estimate Impact of Root Causes on Key Inputs
• Prioritize Root Causes

The team uses different techniques to collect improvement ideas to resolve the issues identified during the Measure Phase. The team identifies idea evaluation criteria to be able to choose between conflicting ideas. Process maps are created based on the various ideas that reduce rework loops, waste, and wait times to guide the team toward a refined process. The team conducts mini testing cycles known as “PDCA” or Plan-Do-Check-Act, which is used to refine the ideas. The inputs and outputs of the Improve Phase include:

• Develop Potential Solutions
• Evaluate, Select, and Optimize Best Solutions
• Develop “To-Be” Value Stream Map(s)
• Develop and Implement Pilot Solution
• Confirm Attainment of Project Goals
• Develop Full Scale Implementation Plan

Once it is proven the refined process has resulted in measurable improvement, the process enters the Control Phase. The Control Phase is based on sustainment of the achieved improvement and becomes part of process management. The team defines the measurements they want to maintain for ongoing monitoring to ensure the process operates at the optimum level. This phase also recommends reviews of the project results to determine if the improvements can be transferred to other areas of the business. The inputs and outputs of the Control Phase include:

• Implement Mistake Proofing
• Develop SOP’s, Training Plan, and Process Controls
• Implement Solution and Ongoing Process Measurements
• Identify Project Replication Opportunities
• Transition Project

Introduction to Minitab statistical software
• Project selection for Green Belts
• Project and team management tools and parameters
• Process mapping
• Introduction to analysis of measurement results
• Understanding customer requirements (CTQs)
• Supplier-Input-Process-Output-Customer (SIPOC)
• Variation – common versus special cause
• Measurement systems analysis (MSA)
• Hypothesis testing
• Process analysis
• Correlation and regression analysis
• Analysis of variance (ANOVA)
• Statistical process control (SPC)
• Control plans
• Mistake proofing
• Improvement plans and techniques
• Cultural assessment tool review
• Control strategies