Day 1

Module Number Subject Slides Instructor Activities time start stop Presentation
1 Introduction (BB mat'l) 1-24 0:20 8:00 AM 8:20 AM 1_GB_Training_Understanding_6_Sigma
2 Strategic Problem Solving 1-19 0:30 8:20 AM 8:50 AM 2_GB_Training with SPS_Introduction
Exercise - Strategic Exercise - Strategic Problem
3 Problem Solving 20 Solving 0:15 8:50 AM 9:05 AM

21-32 0:25 9:05 AM 9:30 AM

Break 0:15 9:30 AM 9:45 AM
2 The Critical Order 33-41 0:30 9:45 AM 10:15 AM
Exercise - The Critical Exercise - The Critical Order
2 Order 42 0:30 10:15 AM 10:45 AM

2 Exercise - Drill Down Tree 43 Exercise - Drill Down (Class) see Instructor notes for Deck of Cards
0:45 10:45 AM 11:30 AM exercise
2 Drill Down Tree Example 44-45 0:05 11:30 AM 11:35 AM
Lunch 1:00 11:35 AM 12:35 PM
2 Five Strategies 46-59 Participants can review Addendum -
0:15 12:35 PM 12:50 PM Phyics Based Problem Solving Strategy
Examples (p.51-62)
2 Exercise - Five Strategies 60 Exercise - Each table put together
example for each of the five 0:45 12:50 PM 1:35 PM
problem solving strategies.
2 Strategic Problem Solving 61-64 0:05 1:35 PM 1:40 PM
Break 0:15 1:40 PM 1:55 PM
3 Define 1-12 0:10 1:55 PM 2:05 PM 3_GB_Training_with_SPS_Define
Exercise - Problem Exercise - Problem Statement
3 Statement 13 1 example/table (project) 0:20 2:05 PM 2:25 PM
Process Mapping/Flow
3 Chart 14 - 27 0:25 2:25 PM 2:50 PM
Case Study - Case Study - Transmission Front
Transmission Front Gear 28 - link to Gear Carrier Case.
3 0:15 2:50 PM 3:05 PM
Carrier Case. addendum

3 Exercise - Process Map 34 Exercise - Process Map

0:20 3:05 PM 3:25 PM
1 example/table (project)
3 CTS vs. KPOV 35 - 46 0:15 3:25 PM 3:40 PM 3_GB_Training_with_SPS_Define
Exercise - CTS/ KPOV Exercise - CTS/ KPOV Handout - H01 CTS-KPOV Exercise Answers
3 47 0:05 3:40 PM 3:45 PM
3 CTS vs. KPOV 48 - 49 0:05 3:45 PM 3:50 PM
3 Exercise - Blue Shirt 50 Exercise - Blue Shirt 0:20 3:50 PM 4:10 PM Handout - H02 Blue Shirt example
Day 2

Review strategic model & five strategies 0:15 8:00 AM 8:15 AM SPS Model and tools, 5 strategies, KPOV
CTS, Project Scope, Y =
3 51 - 61 0:10 8:15 AM 8:25 AM
f(x) cascade
3 Exercise - Y=f(x) cascade 62 Exercise - Y=f(x) cascade
1 example/table (project) 0:10 8:25 AM 8:35 AM
3 Pareto Diagram 63 - 69 0:05 8:35 AM 8:40 AM
Case Study - Romeo 70 - Link to Case Study - Romeo Crankshaft
0:10 8:40 AM 8:50 AM
Crankshaft Case addendum. Case
3 Exercise - Project Scoping 72 Exercise - Project Scoping &
& Refined Problem Refined Problem Statement 0:20 8:40 AM 9:00 AM
Statement 1 example/table (project)
Break 0:15 9:00 AM 9:15 AM
3 Project Charter 73 - 85 0:05 9:15 AM 9:20 AM
3 Exercise - Project Charter 86 Exercise - Project Charter 0:40 9:20 AM 10:00 AM
4 Statistics, DPMO, Histogram 1 - 25 0:15 10:00 AM 10:15 AM 4_GB_Training_with_SPS_Measure
Case Study - Power 26 - Link to Power Case Study - Power Products 4_GB_Training_with_SPS_Measure
4 0:15 10:15 AM 10:30 AM
Products Product example
4 Cause and Effect 27 - 48 0:15 10:30 AM 10:45 AM 4_GB_Training_with_SPS_Measure
4 Exercise - Helicopter C&E 49 Exercise - Helicopter C&E Diagram Appendix - A05 QOSC Flyer Mfg Assy
Diagram 0:15 10:45 AM 11:00 AM Instruction
4 Attribute & Variable Data 50 - 55 0:15 11:00 AM 11:15 AM
4 Exercise - Types of Data 56 Exercise - Types of Data
0:20 11:15 AM 11:35 AM
1 example/table (project)
4 Data Collection 57 - 63 0:15 11:35 AM 11:50 AM
4 Exercise - Sources of Data 64 Exercise - Sources of Data
0:20 11:50 AM 12:10 PM
1 example/table (project)
4 Stratification of Data 65 - 71 0:15 12:10 PM 12:25 PM
Lunch 1:00 12:25 PM 1:25 PM
Exercise - Stratification Exercise - Stratification of Data
4 1 example/table (project) 0:15 1:25 PM 1:40 PM
72
4 Data Collection Tools 73 - 78 0:15 1:40 PM 1:55 PM
Case Study - Crank Shaft 79 - Link to Case Study - Crank Shaft
4 0:10 1:55 PM 2:05 PM
addendum
4 Exercise - Data Collection 80 Exercise - Data Collection
0:10 2:05 PM 2:15 PM
1 example/table (project)
4 Sampling Data 81 - 91 0:05 2:15 PM 2:20 PM
4 Exercise - Data Collection 92 Exercise - Data Collection Plan
0:10 2:20 PM 2:30 PM
Plan 1 example/table (project)
MSA - Walking the Process
4 0:05 2:30 PM 2:35 PM
and Attribute 93 - 111
Break 0:15 2:35 PM 2:50 PM
Exercise - Attribute M&M Exercise - Attribute M&M Appendix - A02 Attribute Data MSA Exercise
Added pareto by color instructions
4 1:00 2:50 PM 3:50 PM Appendix - A03 Attribute R R Example Data
112 Collection
4 Variable Gauge R&R 113 - 120 0:05 3:50 PM 3:55 PM
 4 Variable MSA 121 Link to Follow link to prefered (by
Addendum trainer) Variable GR&R
(Suggest Youden - does not
require computer)
Addendum - Range Method (p.216-218)
Addendum - Average and Range Method
(p.220-223)
0:10 3:55 PM 4:05 PM Addendum - Graphical GRR (Youden
graph) (p.225-229)
Addendum - ANOVA method (p.231-241)

4 Measure 122 - 124 0:05 4:05 PM 4:10 PM

4 Variable Gage R&R 125 Variable Gage R&R Exercise Water Average and Range Method: Appendix - A17
Exercise Cup (method assigned by trainer) Variable RR template
Variable GRR to be completed with 0:00 4:10 PM 4:10 PM
scatterplot exercise in Module 5.

4 Process Capability 126 - 161 0:20 4:10 PM 4:30 PM

Day 3
Review (strategic model, five strategies, & Day 2 concepts) 0:15 8:00 AM 8:15 AM
4 Exercise - Calculate 162 - 164 Exercise - Calculate Process Appendix - A04 PPK Exercise
Process Capability Capability 0:45 8:15 AM 9:00 AM Handout - H03 PPK Exercise Answer
Process Capability and
4 0:15 9:00 AM 9:15 AM
Rolled Throughput Yield. 165 -172
Break 0:15 9:15 AM 9:30 AM
5 strategies, 7 wastes, 5_GB_Training with SPS_Analyze
5 cycle time, X-Y Matrix, 1:15 9:30 AM 10:45 AM
scatter plot, 1 - 72
5 Exercise - Helicopoter 73 -74 Exercise - Scatter Diagram and Appendix - A05 QOSC Flyer Mfg Assy
Scatter Diagram with Youden Plot - The Gravity Instructions
Youden Plot Helicopter (10 helicopter per Appendix - A06 Helicopter Scatter Plot Data
team/table) 1:15 10:45 AM 12:00 PM Sheet
Handout - H04 Helicopter Template (2
helis/page)

Lunch 1:00 12:00 PM 1:00 PM

5 Exercise - Helicopter Exercise - Helicopter Scatter
Scatter Diagram Diagram and Youden Plot report 0:20 1:00 PM 1:20 PM
out
5 Analyze 75 - 80 0:10 1:20 PM 1:30 PM
5 Exercise - Hypothesis 81 - 82 Exercise - Hypothesis Testing
Testing 0:15 1:30 PM 1:45 PM
Break 0:15 1:45 PM 2:00 PM
Tukey, Tools, Drill Down
5 0:30 2:00 PM 2:30 PM
Examples. 83 - 130
Choosing Solutions and 6_GB_Training_with_SPS_Improve
6 Design of Experiments 0:30 2:30 PM 3:00 PM
1 - 47
Exercise - Graphical DOE 47 link to addendum Exercise - Graphical DOE Analysis. Appendix - A08 DOE Exercise
6 Analysis of Data Set Helps prepare for Helicopter DOE. 0:20 3:00 PM 3:20 PM Handout - H05 DOE Exercise Answer Key

Day 4
Review (strategic model, five strategies, & Day 3 concepts) 0:15 8:00 AM 8:15 AM SPS Model and tools, 5 strategies, KPOV
Case Study - Fit and 48 - link to fit and Case Study - Fit and Finish,
Finish finish DOE case Provides students with a 2 factor
6 study DOE before doing Helicopter 0:15 8:15 AM 8:30 AM
DOE.
Break 0:15 8:30 AM 8:45 AM
6 Exercise - Helicopter 49 - 52 Exercise - Helicopter Design of Appendix - A05 QOSC Flyer Mfg Assy
Design of Exeriments Exeriments Instructions
Appendix - A09 Grid Graph Paper (for main
and interaction graph)
Appendix - A10 Helicopter 2 Factor DOE
3:00 8:45 AM 11:45 AM Exercise
Appendix - A11 Helicopter 3 Factor DOE
Exercise
Handout - H04 Helicopter Template (2
helis/page)

Lunch 1:00 11:45 AM 12:45 PM

Case Study - Engine 48 - link to engine Case Study - Engine Leaks at
6 Leaks at Hot Test leak DOE case Hot Test 0:20 12:45 PM 1:05 PM
study
6 Improve 53 - 84 0:10 1:05 PM 1:15 PM
6 Exercise - Validate 85 Exercise - Validate Improvement
Improvement (refer to Z table at Measure p.159) 0:05 1:15 PM 1:20 PM
7 Control 1 - 80 0:40 1:20 PM 2:00 PM 7_GB_Training_with_SPS_Control
Break 0:15 2:00 PM 2:15 PM
Test 1:00 2:15 PM 3:15 PM
Review Test Answers 0:20 3:15 PM 3:35 PM

* Exercises in italics are critical to learning concepts and should not be skipped.
* Case Studies are in BOLD. Every effort should be made to teach each one to reinforce use of strategies and tools in real world situations.