Chương trình đào tạo và huấn luyện thực hành D M A I C Lean Six Sigma Yellow Belt (4 days)

1. Lean Six Sigma Yellow Belt la gi? Vai tro & Tieu chi

Lean Six Sigma Yellow Belt la nguoi tham gia ho tro cac du an cai tien (Improvement Projects) duoc danh dau boi Green Belt hoac Black Belt. Hieu ro triet ly Lean, phuong phap DMAIC, va cac cong cu co ban de tham gia hieu qua vao nhom du an.

Vai tro Yellow Belt:

• Tham gia thu thap du lieu, kiem tra chat luong, thuc hien 5S, Kaizen nho.
• Hieu duoc “Ngon ngu” Lean Six Sigma (CTQ, VOC, VOP, DPMO, Sigma Level, Lead Time, Takt Time…).
• Ung ho Green Belt/Black Belt trong viec thuc hien cac cong cu: SIPOC, VOC, Process Map, 7 QC Tools, FMEA, Control Plan.
• Co the dan dau cac “Quick Win” / “Just-Do-It” tai khu vuc lam viec cua minh.

Tieu chi chon Yellow Belt:

• Van hanh vien, Ky su chat luong, Ky su san xuat, Team Leader, Supervisor.
• Nhan vien van phong, IT, HR, Tai chinh muon hieu ve cai tien quy trinh.
• Khong can co chung chi White Belt truoc (nhung khuyen khich).

2. Tong quan phuong phap DMAIC (5 phien)

3. D – Define (Xac dinh van de & Muc tieu)

Project Charter (Ban ghi du an) – “Hop dong” cua du an:

• Business Case: Tai sao lam du an nay? (Tiet kiem tien, Tang doanh thu, Giam khieu nai, An toan).
• Problem Statement: Mo ta van de bang so lieu: What, Where, When, How big (Dung so lieu, khong dung cam xuc).
• Goal Statement: Muc tieu SMART: Cu the, Do duoc, Dat duoc, lien quan, Co thoi han. Vi du: “Giam ty le loi tu 5% xuong 1% trong 4 thang”.
• Scope (Pham vi): In Scope (Lam gi) / Out Scope (Khong lam gi). Tranh “Scope Creep”.
• Timeline: Gantt Chart voi cac Milestone (Gate Review: D, M, A, I, C).
• Team & Roles: Sponsor, Champion, Black Belt, Green Belt, Yellow Belts, SMEs.

SIPOC (Suppliers, Inputs, Process, Outputs, Customers):

• Ve so do cao cap (High-level) 5-7 buoc cua quy trinh.
• Giup Team hieu “Ai dua gi vao”, “Quy trinh lam gi”, “Ra gi”, “Ai nhan”.

VOC (Voice of Customer) -> CTQ (Critical to Quality):

• Thu thap VOC: Khach hang noi truc tiep, Khau sat, Khieu nai, Du lieu thi truong.
• Chuyen doi VOC -> CTQ (Yeu cau chat luong quan trong). Vi du: “Giao hang nhanh” -> CTQ: “On-time Delivery > 98%”, “Lead Time < 3 ngay".

4. M – Measure (Do luong & Co so du lieu)

Process Map (Ve so do quy trinh) – Chi tiet (Detailed):

• Value Stream Map (VSM) hoac Swimlane Map.
• Xac dinh: Value Added (VA), Non-Value Added (NVA), Business NVA (BNVA).
• Tinh: Lead Time, Cycle Time, %C/O (Changeover), Rolled Throughput Yield (RTY).

Data Collection Plan (Ke hoach thu thap du lieu):

• Bien nao? (CTQ / X). Loai du lieu: Continuous (Lien tuc) vs Discrete (Roi rac/Phan loai).
• Thu thap o dau? (Trong quy trinh).
• Ai thu? Khi nao? So luong mau (Sample size)?
• Cong cu thu: Check Sheet, He thong tu dong, Minitab.

MSA (Measurement System Analysis) – Gage R&R:

• Bat buoc truoc khi thu thap du lieu. Neu he thong do khong tin cay -> Du lieu rac -> Quyet dinh sai.
• Gage R&R (Crossed): %Study Var < 10% (Tot), 10-30% (Chap duoc), > 30% (Khong chap duoc -> Phai cai tien he thong do).
• Attribute Agreement Analysis cho du lieu Phan loai (Pass/Fail).

Baseline Performance (Hien trang):

• DPMO (Defects Per Million Opportunities), Sigma Level (Zst, Zlt).
• Process Capability: Cp, Cpk (Bien lien tuc), Pp, Ppk (Hien trang toan bo).
• Yield: FTY (First Time Yield), RTY (Rolled Throughput Yield).

5. A – Analyze (Phan tich nguyen nhan goc)

Cong cu phan tich nguyen nhan (Root Cause Analysis):

• 5 Whys (5 Tai sao): Hoi “Tai sao?” den 5 lan de tim Root Cause. Don gian, hieu qua cho van de don.
• Fishbone / Ishikawa (Xuong ca): Phan loai nguyen nhan: 6M (Man, Machine, Material, Method, Measurement, Mother Nature/Environment). Team based.
• Pareto Chart (80/20): Tap trung vao 20% nguyen nhan gay ra 80% van de.
• Scatter Plot & Correlation: Tim moi quan he giua X (Nguyen nhan) va Y (Ket qua).

Kiem dinh giai thuyet (Hypothesis Testing) – Minitab:

• Kiem dinh Trung binh: 1-Sample t, 2-Sample t, Paired t, ANOVA (One-way, Two-way).
• Kiem dinh Ty le: 1 Proportion, 2 Proportions.
• Kiem dinh Phuong sai: Test for Equal Variances.
• p-value < 0.05: Co chenh lech co y nghia thong ke. p-value >= 0.05: Khong co chung de ket luan khac biet.

FMEA (Failure Mode and Effects Analysis) – Analyze Phase:

• Xac dinh cac Che do that bai (Failure Modes) cua quy trinh.
• Danh gia: Severity (S), Occurrence (O), Detection (D) -> RPN = S x O x D.
• Tap trung vao cac Failure Mode co RPN cao de tim Root Cause.

6. I – Improve (Cai tien & Kiem thu giai phap)

Sinh ra giai phap (Solution Generation):

• Brainstorming, Benchmarking, TRIZ, SCAMPER.
• Chon giai phap bang Pugh Matrix hoac Solution Selection Matrix (Tieu chi: Tac dong, Chi phi, Thoi gian, Rui ro, Dang tri).

Kiem thu (Pilot) & DOE (Design of Experiments):

• Pilot nho (Small scale): 1 ca, 1 may, 1 dong, 1 tuan. Giam rui ro.
• DOE (Full/Fractional Factorial): Toi uu cac tham so quan trong (Key Process Input Variables – KPIVs) anh huong den Output (KPIV). Tim “Sweet spot”.
• Xac nhan ket qua: Kiem dinh giai thuyet truoc/sau, Capability Analysis (Cpk moi > Cpk cu).

FMEA – Improve Phase:

• Cap nhat FMEA sau cai tien: Giam O (Occurrence), Tang D (Detection).
• RPN moi phai thap hon RPN cu rong rai.

7. C – Control (Kiem soat & Duy tri)

Control Plan (Ke hoach kiem soat) – “Polis bao hiem” cho ket qua:

SPC (Statistical Process Control):

• Chon dung Control Chart: Xbar-R, I-MR, P, NP, C, U.
• Gioi han kiem soat (UCL, LCL) khac voi Spec (USL, LSL).
• Quy tac phat hien Special Cause: Western Electric Rules (Nelson Rules).

Standard Work (Cong viec chuan) & Visual Management:

• Tac time, Work Sequence, Standard WIP.
• Visual: Andon, Kanban, Shadow Board, Kamishibai Board.

Mistake Proofing (Poka-Yoke):

• Phong ngua (Prevention): Khong the lam sai duoc (Vi du: Khoa hinh dang, Cam bien).
• Phat hien (Detection): Bao ngay khi sai (Vi du: Dem so luong, Can kiem tra).

8. A3 Report & Trinh bay ket qua

A3 Report (Giay A3 mot mat) la cong cu bao cao quan ly du an Lean, tuan thu PDCA:

• Background / Business Case (Left Top)
• Current State / Problem (Left Mid): VSM, Data, Pareto.
• Goal / Target (Right Top)
• Root Cause Analysis (Right Mid): Fishbone, 5 Whys, Hypothesis Test.
• Countermeasures / Solutions (Left Bottom): Pugh Matrix, Pilot Results.
• Implementation Plan (Right Bottom): Gantt, Owner, Due Date.
• Results / Follow-up (Bottom): Before/After, Control Plan, Lessons Learned.

9. Lich hoc 4 ngay & Chung chi

Chung chi:

• CiCC Yellow Belt Certificate: Hoan thanh 4 ngay, Tham gia du 100%, Dat diem kiem tra > 70%, Hoan thanh A3 du an mau.
• ASQ CSSYB Exam Prep: CiCC ho tro on thi chung chi ASQ Certified Six Sigma Yellow Belt (CSSYB).
• IASSC ICYB Exam Prep: Ho tro on thi IASSC Lean Six Sigma Yellow Belt (ICYB).

10. Lien he

Hotline: 098 905 1920 (Chi Dung)

Email: dung.truong@lean.vn

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