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Quality Management

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