Lean Six-Sigma Green Belt Certification Program

Introduction:

This high impact program skillfully trains the participant to become a Lean Six-Sigma Green Belt professionals. This course enhances professional core competencies in World-Class business processes. Additionally, participants are better qualified to increase operational effectiveness, engage employees, reduce operating expenses, improve industry reputation, and leverage business excellence. Customer value creation awareness is a prime element of this unique training initiative.

Targeted Groups:

• Quality Assurance Professionals
• Managers, Supervisors, and Professionals who wish to fully utilize Six Sigma approach in their organizations

Course Objectives:

At the end of this course the participants will be able to:

• Enhance their understanding of the basic level Lean Six-Sigma process.
• Learn to successfully deploy Six-Sigma into current business operations for effectiveness through teamwork.
• Learn the basics of Lean Six-Sigma methodology, statistical analysis, and its analytical integration into the business process.
• Learn to integrate the principles of Lean Six-Sigma to establish process control and minimize process variation, subsequently, reducing operational costs.
• Develop their understanding of the skills and behaviors required to fully deploy Lean Six-Sigma into your organization.
• Understand how to deploy the potential of Lean Six-Sigma as a strategic business tool.
• Learn the basics of Lean Processing and Six-Sigma applications to focus on the reduction of operational costs.
• Learn to maximize profits by reducing process variation and expanding operational control and stability.
• Re-define their perception of “normal” to “excellent” with the skillful application of Lean Six-Sigma tools.

Targeted Competencies:

• Deploying Six Sigma
• Problem-solving skills
• Critical thinking skills
• Using applied statistics
• Lean principles

Course Content:

Unit 1: Understanding The Strategic Power of Six-Sigma Methodology:

• VOC, stakeholders & process owners, CTQ elements
• The basis of Six-Sigma; history and development; Understanding DMAIC process
• Strategic concepts & benefits of Benchmarking
• Six-Sigma deployment: DMAIC Concept
• Tollgate concept for Six-Sigma organizational functionality
• The power of data analysis in organization effectiveness and clarification
• Concepts of the Kano Analysis…three key elements of customer awareness
• Six Sigma in action. Project charters…Six-Sigma project integration
• The impact of lean process and Six Sigma, the perfect algorithm
• “Do It Yourself Six-Sigma” The application of Project Templates
• Defining Timelines and Deliverables…a clear project game plan
• The focus on value creation in business processes
• “Speed and Accuracy” Blending proven processing concepts
• Quality function deployment (QFD) for business operations
• Six Sigma as a Strategic Strategy and a Measurement of organizational quality
• Data-driven decision making…removing subjectivity in business decisions
• Key Metrics & Drivers for Organizational effectiveness market share
• World-Class Transformation to enhance competitiveness
• Kano analysis; three levels of customer responsiveness

Unit 2: Six-Sigma Deployment for Organization Effectiveness:

• Calculation: The costs of poor quality: COPQ; Understanding ROI
• Attribute and Continuous Data…recognizing the differences for application
• Descriptive and Inferential statistics…knowing when to use what
• Histograms. Measures of central tendency…normal statistical distributions
• Normal Distributions, Standard Scores, Z tables
• Student’s t-Tests, statistical degrees of freedom
• Process Capability - voice of the process; central tendency of the data set
• Statistical Mean, Median & Mode; Calculation of Sigma Failure Rates; DPMO
• Microsoft Excel & Minitab Statistical Software Applications
• Process Base Line; Data Collection Plan
• Y= f x - Matrix; Identification of KPIV
• Graphing Discrete & Continuous Data; software interface
• Graphing Discrete & Continuous Data; software interface
• Population & Sample data
• Central Limit Theorem, confidence intervals
• Hypothesis Testing for the mean, Type I & Type II Errors, alpha risks
• Process Capability
• Process Tolerance, Measures of Dispersion, central tendency, Cp & Cpk,
• Statistical (natural process) Limits & Customer Specification Limits: LCL & UCL
• Bivariate data analysis in Six-Sigma applications
• Gauge R&R; Measurement Systems Analysis (MSA)

Unit 3: Concepts of Lean Processing:

• History of Lean Manufacturing
• Lean Analysis: transformation from current state to future state
• Cycle Time Compression; improving process throughput
• Supply Chain Acceleration
• Value Stream Mapping; focus on value creation: value chain identification
• Muda: Identifying Seven Types of Wastes
• Muri: Work complexity & fatigue factors
• Mura: Focus on Process Flow; Roll Throughput Yield RTY
• 5S concepts for workplace organization & effectiveness
• Visual controls, Poka Yoke concept; prevention/detection/mitigation
• SMED Concepts to speed up processes
• Team dynamics, Team conflict: (forming, storming, norming, performing)
• SIPOC Diagrams; three levels of Process maps, flowcharts

Unit 4: Blending Lean Principles in Business Processes:

• Standardized Work Applications to maximize efficiency and reduce variation
• Batch & Queue VS Single element processing
• Kanban Inventory operational systems
• Understanding the Theory of Constraints
• Total Productive Maintenance (TPM ) for operational costs reduction
• The effective integration of RFID/bar codes
• Employee Empowerment for organizational effectiveness/Kaizen interface *
• Point of Use Supply
• Quality at the Source
• Green Process Integration
• Six-Sigma project work/team dynamics and interaction
• Cause & Effect Diagrams: Ishikawa/fishbone chart Analysis
• FMEA Matrix applications for Six-Sigma; calculating the RPN
• Production Balance: The Importance of TAKT Time Awareness
• Project tools: Gantt charts, critical path method (CPM) & PERT evaluation
• Brainstorming for Results, Pareto Analysis 80/20 Analysis*
• Improving the Process for effectiveness; Lean process & Six-Sigma Integration
• High-level Green Analysis
• Ishikawa Diagrams, Brainstorming, Pareto 80/20
• Brainstorm for Project Benefits…integration of team dynamics: the Five whys

Unit 5: Skillfully Applying the Tools of Six-Sigma for Success:

• Tools to speed analysis…finding the root cause of variation
• Measuring and tracking improvement; Establishing Process Baseline
• Hold the line... standardization/optimization
• Tools to prioritize improvement opportunities
• Successful ways to define and mitigate failure modes
• FMEA Diagrams in Action…how to identify process trouble spots
• Project Closure; Control plans that WORK!
• Continued workplace training...SOP for succession planning for success;
• Innovative Six-Sigma deployment opportunities
• SPC; Monitoring Systems, Locking the Learning
• Control Chart Utilization; Juran, Deming, & Shewhart