Lean Six-Sigma Green Belt

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.

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.

Course Coverage

Topic 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

Topic 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)

Topic 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

Topic 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

Targeted Participants:

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