Lean Six Sigma In Engineering Projects Training Course

Introduction

In today's highly competitive and quality-driven engineering landscape, integrating Lean Six Sigma methodologies is crucial for optimizing processes, reducing waste, and driving significant improvements in project efficiency and product quality. This essential training course is meticulously designed to equip engineering professionals, project managers, and quality assurance specialists with the practical tools and strategic mindset to implement Lean Six Sigma principles within their projects. Participants will gain a robust understanding of the DMAIC (Define, Measure, Analyze, Improve, Control) roadmap, Lean principles for waste reduction, and Six Sigma statistical techniques for defect prevention, enabling them to deliver projects with higher quality, lower costs, and faster timelines. Our comprehensive curriculum emphasizes hands-on application, real-world case studies, and practical exercises pertinent to the dynamic industrial, manufacturing, and construction sectors in Kenya, empowering you to achieve operational excellence.

This process improvement for engineers course is crucial for individuals and organizations in Kenya striving for enhanced productivity, reduced operational expenditures, and superior customer satisfaction. Mastering Lean methodologies for engineering, implementing Six Sigma quality control, and understanding process optimization in projects are indispensable for identifying bottlenecks, eliminating non-value-added activities, and achieving sustainable performance gains. This program offers an unparalleled opportunity to elevate your expertise in continuous improvement strategies and data-driven decision-making for engineering projects, positioning your organization as a leader in operational efficiency and driving sustained economic growth across East Africa.

Target Audience

• Project Engineers
• Quality Managers/Engineers
• Process Improvement Specialists
• Manufacturing Engineers
• Design Engineers
• Operations Managers
• Anyone involved in process optimization and quality control in engineering projects

Course Objectives

• Understand the fundamental principles and complementary nature of Lean and Six Sigma.
• Master the DMAIC (Define, Measure, Analyze, Improve, Control) methodology for project improvement.
• Learn to identify and eliminate waste (Muda) using Lean tools and techniques.
• Develop proficiency in Six Sigma statistical tools for process variation reduction.
• Apply Lean Six Sigma to enhance efficiency and quality in engineering projects.
• Understand how to define project problems and goals clearly (Define phase).
• Learn to measure current process performance and collect relevant data (Measure phase).
• Develop skills in analyzing root causes of defects and inefficiencies (Analyze phase).
• Learn to implement effective solutions and process improvements (Improve phase).
• Understand how to sustain gains and control improved processes (Control phase).
• Explore the role of Lean Six Sigma in project selection and benefits realization.
• Drive a culture of continuous improvement and data-driven problem solving.
• Enhance problem-solving capabilities and decision-making for complex engineering challenges.

DURATION

10 Days

COURSE CONTENT

Module 1: Introduction to Lean Six Sigma module

• What is Lean? Principles of waste reduction (Muda, Mura, Muri)
• What is Six Sigma? Focus on variation reduction and defect elimination
• The history and evolution of Lean Six Sigma
• Benefits of integrating Lean and Six Sigma in engineering projects
• Overview of the DMAIC methodology for problem-solving

Module 2: Define Phase module

• Project selection and problem definition
• Creating a Project Charter for Lean Six Sigma initiatives
• Identifying process stakeholders and their requirements
• Voice of the Customer (VOC) analysis and CTQs (Critical To Quality)
• High-level process mapping (SIPOC diagram)

Module 3: Measure Phase module

• Defining process performance metrics and data types
• Data collection plans and sampling techniques
• Measurement System Analysis (MSA) for data validity
• Basic statistical analysis for process data (mean, median, standard deviation)
• Process capability analysis (Cp, Cpk)

Module 4: Analyze Phase module

• Identifying potential root causes of problems
• Process mapping (Value Stream Mapping, Flowcharts) for waste identification
• Fishbone diagrams and 5 Whys for root cause analysis
• Hypothesis testing (conceptual overview) for validating causes
• Data stratification and Pareto charts

Module 5: Improve Phase module

• Brainstorming and selecting potential solutions
• Lean tools for improvement (e.g., 5S, Standard Work, Poka-Yoke, Kanban)
• Piloting and testing solutions
• Risk assessment of proposed improvements (FMEA - conceptual)
• Developing an implementation plan

Module 6: Control Phase module

• Sustaining the improvements over time
• Statistical Process Control (SPC) and control charts
• Developing a control plan for the improved process
• Standard operating procedures (SOPs) and training
• Handover and project closure for Lean Six Sigma initiatives

Module 7: Lean Principles and Tools in Engineering module

• Value Stream Mapping for identifying waste in engineering processes
• 5S methodology for workplace organization and efficiency
• Just-in-Time (JIT) and pull systems in manufacturing/construction
• Error-proofing (Poka-Yoke) in design and production
• Standard work for consistency and quality

Module 8: Six Sigma Statistical Tools in Engineering module

• Understanding process variation and its impact
• Histograms, scatter plots, and run charts for data visualization
• Introduction to Minitab/SigmaXL (conceptual) for statistical analysis
• Correlation and regression analysis (basic)
• Hypothesis testing for process comparisons (basic)

Module 9: Lean Six Sigma Project Implementation module

• Selecting appropriate Lean Six Sigma projects in engineering
• Assembling and leading Lean Six Sigma teams
• Overcoming common challenges in implementation
• Change management strategies for process improvement
• Project reporting and benefits realization

Module 10: Case Studies and Advanced Concepts module

• Real-world Lean Six Sigma case studies from engineering sectors in Kenya
• Applying Lean Six Sigma in design (DFSS - Design for Six Sigma, conceptual)
• Integration with other methodologies (e.g., Agile, Project Management)
• Organizational culture for continuous improvement
• Q&A and practical exercises for specific engineering process challenges

Training Approach

This course will be delivered by our skilled trainers who have vast knowledge and experience as expert professionals in the fields. The course is taught in English and through a mix of theory, practical activities, group discussion and case studies. Course manuals and additional training materials will be provided to the participants upon completion of the training.

Tailor-Made Course

This course can also be tailor-made to meet organization requirement. For further inquiries, please contact us on: Email: info@skillsforafrica.org, training@skillsforafrica.org  Tel: +254 702 249 449

Training Venue

The training will be held at our Skills for Africa Training Institute Training Centre. We also offer training for a group at requested location all over the world. The course fee covers the course tuition, training materials, two break refreshments, and buffet lunch.

Visa application, travel expenses, airport transfers, dinners, accommodation, insurance, and other personal expenses are catered by the participant

Certification

Participants will be issued with Skills for Africa Training Institute certificate upon completion of this course.

Airport Pickup and Accommodation

Airport pickup and accommodation is arranged upon request. For booking contact our Training Coordinator through Email: info@skillsforafrica.org, training@skillsforafrica.org  Tel: +254 702 249 449

Terms of Payment: Unless otherwise agreed between the two parties’ payment of the course fee should be done 10 working days before commencement of the training.