Lean Six Sigma

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Lean Six Sigma Courses

1- Lean Six Sigma Yellow Belt – 20 hours
2- Lean Six Sigma Green Belt – 32 hours
3- Lean Six Sigma Black Belt – 48 hours
1- Lean Training and Certification – 16 hours

Lean Six Sigma Yellow Belt
20 hours training course

Yellow Belt Training is a great way for you, your team or your entire organization to learn the fundamentals of Lean Six Sigma. This Lean Six Sigma training is a high level overview that quickly and effectively builds awareness and covers the following concepts and tools.

 

Introduction to Lean Six Sigma

  • What is Lean Six Sigma?
  • Where did it originate?
  • Why is it so effective and popular?

Lean Six Sigma Roles

  • Yellow Belt
  • Green Belt
  • Black Belt
  • Master Black Belt
  • Champion

The 8 Wastes

  • Defects
  • Overproduction
  • Waiting
  • Non-Utilized Employees
  • Transportation
  • Inventory
  • Motion
  • Extra Processing

DMAIC Overview

  •  Define Phase – How to define the problem.
    •  Project Charter (Tool)
    • Defining Value: Voice Of the Customer (VOC) (Tool)
    • High Level Process Map: SIPOC (Tool)
  • Measure Phase – How to measure the current process.
    • Selecting Measures
    • Data Collection Planning
    • Operational Definitions
    • Capturing Baseline Data
  • Analyze Phase – How to identify the cause of the problem.
    • Process Analysis
    • The Five Whys and The Fishbone Diagram (Tool)
    • Pareto Charts (Tool)
    • Develop a Hypothesis
  • Improve Phase – How to implement and verify the solution.
    • Optimize Flow
    • Mistake-Proofing: Poka-Yoke (Tool)
    • Visual Management and 5S
  • Control Phase – How to maintain the solution.
    • Process Control Plan (Tool)
    • Monitoring and Response Plan (Tool)
    • Documentation and Storyboard

Lean Six Sigma Green Belt course outlines
32 Hours

Lean Six Sigma quality-improvement methods focus on reducing defects, streamlining processes, and improving product quality. This program focuses on the main steps in the Lean Six Sigma approach. Green Belt training provides individuals with a methodology and tools to deliver successful projects as a Lean and Six Sigma project team member. Teams will be established during the course and are expected to identify a project they can work on. Throughout the training, in teams of three to four, they will have the opportunity to apply concepts and techniques. This training will allow employees to be valuable assets to drive the organization goals and objectives in the future.

Lean Six Sigma Green Belt Certification

To achieve a CEG Lean Six Sigma Green Belt Certification, each participant must successfully complete the course, which includes attending all sessions, completing assignments, passing a final exam, and completing a relevant team project within 12 months of the class end-date.

Who should attend

Green Belt Training is targeted for core team members who will be focused on tools usage and DMAIC and Lean Principles for process improvement projects.

What you will achieve

  • Understand and apply the Lean and DMAIC models as a framework to drive process improvement activities.
  • Learn and apply skills in process management, Lean, change management, and basic statistical analysis to business issues.
  • Apply basic statistical analysis to determine the relationship between key inputs and outputs.
  • Transition projects from phase to phase using DMAIC.
  • Define both bottom-line and soft cost savings from improvements.

What you will learn
Course Outline

Module 1: Overview of Lean Six Sigma

  • Process Improvement
  • Key Six Sigma Concepts
  • Exercise: Methodology Selection
  • Green Belt Roadmap
  • Exercise: Reinforcing the Six Sigma Mindset

Module 2: Define Phase

  • Project Selection
  • Team Charter
    • Exercise: Develop a Charter Using Your Team Project
  • Focus on the Customer
    • Exercise: Voice of the Customer (VOC)
  • High Level Process Map: COPIS
    • Exercise: Analyze a Process Using COPIS
  • Team Dynamics and Performance
    • Exercise: Constructive Conflict

Module 3: Measure Phase

  • Exercise: Inspection
  • Define Measurement
    • Exercise: Identifying Output and Input Measures
  • Collect Data
    • Exercise: Classifying Measurements
    • Exercise: Creating and Interpreting a Pareto Chart
    • Exercise: Operational Definitions
  • Understand Variation
    • Exercise: Identify Variation
    • Exercise: Defining an Acceptable Sigma

Module 4: Analyze Phase

  • Identify Possible Causes
    • Exercise: Analyze Preliminary Data
    • Exercise: Variance and Standard Deviation
    • Exercise: Create a Stem-and-Leaf Plot
    • Exercise: 8 Forms of Waste
    • Exercise: Applying 5S Using Your Team Project
  • Narrow to Root Causes
    • Pareto Charts and Stratification
    • Exercise: Cause and Effect (Fishbone) Diagrams
    • Exercise: Using 5 Whys
    • Exercise: Correlation and Regression Analysis
    • Run Charts
  •  Quantify the Opportunity
    • Exercise: Quantifying the Opportunity Using Team Projects

Module 5: Improve Phase

  • Identify and Synthesize Solutions
    • Exercise: Use the Various Types of Brainstorming
    • Exercise: Applying Idea Synthesis Tools to Your Team Project
  • Select Solutions
    • Exercise: Must-Have Criteria
    • Input/Effort Matrix
    • N/3 Process
    • NGT Process
    • Exercise: Apply Prioritization Tools to Team Project
    • Exercise: Criteria-Based Matrix
    • Exercise: High-Level Cost Benefit Analysis
  • Pilot Solutions
    • Plan-Do-Check-Act
    • Exercise: Build an FMEA
    • Exercise: Plan and Run a Pilot
  • Implement Full-Scale Solutions
    • Mistake-Proofing
    • Troubleshooting
  • Change Leadership
    • Exercise: Elevator Speech
    • Exercise: Create a Shared Need

Module 6: Control Phase

  • Exercise: The Power of Control
  • Update Documentation
    • Standardization
    • Exercise: Process Management Plan
  • Monitor Process
    • Exercise: Establish a Monitoring Rhythm
    • Exercise: Control Charts
  • Manage Process
    • Exercise: Develop Communication Plan for Team Project
    • Exercise: Visual Management Systems
  • Closing Thoughts and Action Planning

Lean Six Sigma Black Belt Course
48 hours

Our Lean Six Sigma Black Belt Training & Certification course will enable you to manage process improvement programs and help you become a better leader.

Pre-Requisite:

Lean Six sigma Green Belt Training and Certification

Introduction to Black Belt Training :

  • Overview of Black Belt Training
    • The Road to Black Belt Certification
    • Black Belt As Coach
    • PDCA (Plan Do Check Adjust)
  • Project Selection – Advanced
    • Strategic Alignment With Project Selection
    • Project Selection Facilitation
  • Build Leadership Skills
    • Purpose and Project Work
    • Influence Strategies
    • Facilitation of High-Performing Teams

Module 2: Define Phase

  • Conduct Process Walks
    • Facilitator Guidelines
  • Strengthen Leadership Skills
    • Coach Approach
    • Influence Strategies – Build Ownership
    • Facilitation Skills – Make Meetings Work
  • About Your Black Belt Project
    • Best Practices for Completing a Project

Module 3: Measure Phase

  • Lay Statistical Groundwork
    • Data Types
    • Basic Statistical Terms
    • Normality and Distributions
      • Anderson-Darling Test for Normality
  • Test Your Measurement System
    • Test Your Measurement System: Continuous Data
      • Gage R&R – Discrete
      • Gage R&R – Continuous
    • Test Your Measurement System: Discrete Data
  • Sample the Data
    • Sampling Strategy
    • Sampling Calculations
  • Assess Process Capability
    • Process Capability for Continuous Data
      • Cpu, Cpl, Cpk
  • Strengthen Leadership Skills
    • Coach Approach
    • Influence Strategies – Think Ahead
    • Facilitation Skills – Make Good Decisions
  • About Your Black Belt Project
    • Best Practices for Completing a Project

Module 4: Analyze Phase

  • Lay Hypothesis Testing Groundwork
  • Test Discrete Data
    • 1-Proportion
    • 2-Proportion
    • Chi-Square Test
  • Test Continuous Normal Data
    • Test for Two Variances (F-Test)
    • Bartlett’s Test
    • One-Sample T-Test
    • Two-Sample T-Test
    • 1-Way ANOVA Test
  • Test Continuous Non-Normal Data
    • Levene’s Test
    • One-Sample Sign Test
    • Mann-Whitney Test
    • Moods-Median Test
  • Test Correlation
    • Regression Test
    • Multiple Regression Test
  • Strengthen Leadership Skills
    • Coach Approach
    • Influence Strategies – Pave the Way
    • Facilitation Skills – Drive Team Performance
  • About Your Black Belt Project
    • Best Practices for Completing a Project

Module 5: Improve Phase

  • Design Experiments
    • DOE – One Factor At a Time
    • DOE – Two Factorial
    • DOE – Full Factorial
  • Strengthen Leadership Skills
    • Coach Approach
    • Influence Strategies – Change Management
    • Facilitation Skills – Build Networks
  • About Your Black Belt Project
    • Best Practices for Completing a Project

Module 6: Control Phase

  • Select Control Charts
    • I & MR Chart
    • X-Bar & R Average and Range Chart
    • X-Bar & S Average and Standard Deviation Chart
    • P Chart
    • nNP Chart
    • C Chart
    • U Chart
  • Create Visual Management
  • Strengthen Leadership Skills
    • Coach Approach
    • Influence Strategies – Maintain the Gains
    • Facilitation Skills
  • About Your Black Belt Project
    • Best Practices for Completing a Project

Lean training
16 hours

Lean Training is the most practical, cost-effective way for you, your team or your entire organization to learn and begin applying Lean tools and concepts. It’s an in-depth, interactive, fun online course that quickly and effectively builds your process improvement and project management skills by covering the following concepts and tools.

Introduction to Lean

  • What Is Lean?
  • The History of Lean
  • The Focus of Lean
  • What Is a Lean Process?
  • Why Do Organizations Use Lean?
  • The Cost Of Poor Quality
  • Focus On the Process
  • Lean Principles
  • How Do You Define Value?
  • What Is Flow?
  • The Concept Of Pull
  • The Impact Of Pull
  • How Do You Pursue Perfection?

Lean Tools and Concepts to Establish Current State

  • PDCA
  • A3
  • 8 Wastes
  • Organizational Level Process Map
  • Value Stream Map (VSM)
  • Swimlane Map
  • Process Walk
  • Spaghetti Chart
  • Customer Value
  • Lean Metrics
  • Process Analysis
  • Value Stream Map Analysis
  • Histogram
  • Pareto Chart
  • The 5 Whys & The Fishbone Diagram

Lean Tools and Concepts to Develop Future State

  • Single Piece Flow & Batch Reduction
  • Changeover Reduction
  • Work Cell Design
  • Workload Balancing & Demand Levelling
  • Cross Training
  • Kanban & Supermarkets
  • Standard Work
  • Visual Management
  • 5S
  • Value Stream Map Future State
  • Quick Wins
  • Rapid Improvement Event (Kaizen Event)
  • Pilots
  • Multi-Phase Implementation
  • Mistake-Proofing (Poka Yoke)
  • Pursue Perfection

Lean Tools and Concepts to Build a Lean Culture

  • Leader Standard Work (LSW)
  • Leader Task Boards
  • A3 Coaching
  • Leader Process Performance Boards
  • Leader Huddle Meetings
  • Leader Process Walks
  • Meeting Productivity
  • Stakeholder Analysis
  • Communication Plan

Note: the Lean Training and Certification course could be taken after the green belt course.

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