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Lean Six Sigma Roadmap

Course Description

Print-friendly Course Description and Outline

The fundamental objective of the Six Sigma methodology is the implementation of a measurement-based strategy that focuses on process improvement and variation reduction. Six Sigma seeks to improve the quality of process outputs by identifying and removing the causes of defects (e.g., errors) and minimizing variability in business processes by using a set of quality management and statistical tools.

The purpose of this course is to expose participants to some of the basic Six Sigma tools that can be used during the planning and fieldwork phases of an internal audit to enhance audit effectiveness, provide deeper insight into business operations, and identify process streamlining opportunities. These tools can be used independently or in conjunction with existing audit methodologies, tools, and techniques. Participants will have the opportunity to practice and apply the skills learned during the course through case study and exercises, which should enable them to integrate the tools and techniques into their audit engagement activities. 

This course is appropriate for auditors at all levels.

 
Course Duration: 3 day(s)
CPE Hours Available: 24
Knowledge Level: Intermediate
Field of Study: Auditing
Prerequisites: 
It is suggested that participants come with a basic knowledge of business process auditing; however, it is not required. 
Advance Preparation: 
​None
Delivery Format: On-site Training (Group-Live)

​Unit Two: Six Sigma Overview

  • Describe the relationship of the Lean Six Sigma process improvement methodology to The IIA’s International Standards for the Professional Practice of Internal Auditing.
  • Correlate the Lean Six Sigma process improvement model (DMAIC) to the five phases of an internal audit.
  • Explain the necessity of each business unit’s objectives being aligned with the organization’s overall objectives.

Unit Three: Project Charter

  • Prepare a project charter stating the scope, outlining the objectives, and delineating the roles and responsibilities for a project.
  • Explain the purpose and importance of the project charter.
  • Describe the three main uses of the project charter.
  • Describe what every project charter should include.
  • Create a project charter given a set of facts and circumstances surrounding a business process improvement project.

Unit Four: Value Stream Mapping

  • Map the Value Stream of a given process to analyze the flow of materials and information required to bring a product or service to a customer.
  • Explain the importance of quantification in a Value Stream Map.
  • Describe how customer value is tracked within a Value Stream Map.
  • Describe the business process component categories captured in a Value Stream Map.
  • Construct a Value Stream Map for capturing a business process.

Unit Five: Spaghetti Diagrams

  • Construct an “As-Is” Spaghetti Diagram, adapted from a process flowchart, that highlights the number of key steps and spatial relationships of a particular process.
  • Explain the purpose of an “As-Is” Spaghetti Diagram.
  • Demonstrate how an “As-Is” Spaghetti Diagram is adapted from a process flowchart.
  • Capture the key steps and spatial relationships in a business process.
  • Identify and Eliminate the superfluous steps in a "To-Be" Spaghetti Diagram
  • Examine the spatial relationships of the key steps in a "To-Be" Spaghetti Diagram and develop a more streamlined process path.

Unit Six: Control Charts

  • Explain the purpose and importance of process analysis
  • Measure the performance of a process using a control chart
  • Assess the capability of a process using a control chart.

Unit Seven: Cause & Effect (Fishbone) Diagrams and 5 Whys

  • Explain the purpose and importance of Root Cause Analysis.
  • Explain the purpose and importance of Cause & Effect (Fishbone) Diagrams.
  • Describe the six categories of Cause & Effect (Fishbone) Diagrams.
  • Construct and Utilize a Cause & Effect (Fishbone) Diagrams for determining the root cause of an issue or problem.
  • Employ the Questions-Asking method for determining the root cause of an issue or problem.
  • Describe the two techniques for using the 5 Whys method.

Unit Eight: Pareto Chart

  • Explain the purpose and importance of a Pareto Chart
  • Demonstrate root cause analysis using a Pareto Chart.
  • Determine the scope of the process for which Pareto Analysis will be employed.
  • Describe risk analysis using a Pareto Chart.
  • Construct a Pareto Chart to prioritize process failure issues.

Unit Nine: Theory of Constraints

  • Explain the purpose and importance of the Theory of Constraints.
  • Describe the Five Focusing Steps related to the Theory of Constraints.
  • Explain the significance of constraints in the Theory of Constraints.
  • Explain the use of buffers in the Theory of Constraints.
  • Describe the Five Thinking Process an organization uses to support the Theory of Constraints.

Unit Ten: Failure Modes & Effects Analysis (FMEA)

  • Explain the purpose and importance of an FMEA
  • Describe the goals of an FMEA
  • Identify the timing of an FMEA
  • Perform an FMEA given a set of facts and circumstances surrounding a business process.

Unit Eleven: Poka-Yokes

  • Explain the use of Poka-Yokes in mistake-proofing business processes
  • Describe the types of errors in a business process that Poka-Yokes are designed to address
  • Characterize effective mistake-proofing techniques
  • Develop Poka-Yokes to mistake-proof a business process.

Unit Twelve: Wrap-Up and Next Steps

  • Apply concepts, techniques, and skills learned in the workplace.
  • Restate major concepts, techniques, and skills learned during the course.
  • Develop an action plan to apply selected concepts, techniques, and skills.
 

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