Introduction to Lean 6 Sigma

Course dates: 30 April & 1 May 2009 to be re-scheduled       Venue:

Course fees: £1160.00 + VAT

Course Objectives

In this two day introductory course

• Participants will learn how pharmaceutical processes can be improved by using two powerful approaches: Lean Thinking and Six Sigma. “Process” here means any series of linked activities in the plant, laboratory or office.
• The principles and practice of Lean Thinking and Six Sigma will be introduced and explored using examples and exercises from R&D, development and manufacturing.
• The potential for Lean Thinking and 6 Sigma (Lean 6 Sigma) to increase quality, reduce costs and speed up processes will become clear.

By the end of the course you will understand how

• Lean thinking focusses on the customer, and identifies and removes waste – taking out all activities that do not add value for the customer. "Customer" is anyone who receives work from someone else. In the lean workplace, work flows rapidly from the suppliers to the customer. Lean means involving all staff in continuous improvement of their processes.
• Six Sigma seeks to identify and drive out variation in the process. Statistical methods are used widely and deeply to find root causes and control variation. Six Sigma processes reliably and robustly meet the customers’ needs. Six Sigma is project-based via the Define-Measure-Analyse-Improve-Control method. (Please note that there will only be time on this course to briefly mention statistical methods that are available.)
• The Theory of Constraints identifies and manages the rate-determining step of a process system, and works well in combination with Lean and Six Sigma.
• Involving people is the key to successful improvement; there are tried and tested methods for change management and embedding change.

Who Should Attend

• This course will be suitable for anyone involved in pharmaceutical R&D, development or manufacture who wants an introduction to process improvement methods.
• Pharmacists, chemists, engineers and clinical project teams & scientists will benefit.
• The training will start from first principles for those with no prior knowledge of Lean and Six Sigma, but those with some knowledge will also benefit from this interactive course.

Speaker: Dr Steve Carleysmith

Programme:

Lean Thinking – drive out wastes; flow the work

• The Five Steps of Lean
• History and context
• The value stream
• Customer focus
• Process thinking – value stream mapping
• The seven wastes and the cost of poor quality
• The lean toolbox

Six Sigma – drive out variation

• Variation and distribution
• Sigma capability
• Why “Six Sigma”?
• Voice of the process
• Undesirable effects and root cause analysis
• The DMAIC process (define, measure, analyse, improve, control)
• The statistics toolbox
• Design for Six Sigma and QbD (Quality by Design)

Lean 6 Sigma

• Using the powerful combination

The Theory of Constraints

• Knowing what’s slowing you, and using it

People and change management

• The Project Initiation Document and Project Charter
• Getting and sustaining improvement

Back in the workplace

• Starting your own project.