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Lean Six Sigma: GreenBelt

PROGRAM SUMMARY

    1. 5-day Lean Sigma Yellow Belt Certification (Option: Spread in 2-5 weeks) 
    2. Equips participants with the most common tools used in Lean Six Sigma for Manufacturing, BPO, Supply Chain and Services.
    3. Package will include Project Coaching and Toll Gate Reviews. 
    4. International Certification from Six Sigma Experts (USA). 
    5. Nurture online community of students: Forum for questions, Online coaching, VLOGs by Six Sigma Coach (@sixsigmacoachph),Articles by Coaches and Students

 

Course Overview:

We live in a very competitive and global environment. Right before our eyes, businesses evolve and transform, products and services need to satisfy different levels of perfection year after year, as companies pursue customer satisfaction and delight.

Organizations who have acknowledged this, have found the Lean and Six Sigma Program to be an effective, structured, data-driven, way to performance improvement and transformation. 

To affect this, change agents who will guide, support and lead. These team leaders are called Lean Six Sigma GREEN BELTS. The Green Belt is equipped with a working knowledge and application of the tools and methodology of Lean and Six Sigma in various operations, effecting incremental reduction in Cost, improvement in Cycle Time, Defect Reduction, Quality improvement, higher efficiency resulting into superior business results.

This program is aimed to train and certify existing Process Experts in the Lean-Six Sigma Green Belt body of knowledge and its application in the workplace.

This 5-day Green Belt training and certification workshop program spread over a period of 1 month,  will enable the qualified candidate absorb, assimilate and apply the tools and methodology. Relevant exercises and multi-media materials will also be used to ensure adequate knowledge absorption and retention.

 

Course Objectives:

The learning expectations of the participants are the following:

  •   Thorough understanding and application of  the Lean-Six Sigma methodology, its process improvement tools and techniques to various operational and business models.
  • Learn how to develop the different work deliverables in each stage of the DMAIC cycle.
  •   Learn how to manage Lean-Six Sigma projects, mentor Six Sigma Yellow Belts and team members.
  •   Add value to the organization by defining and pursuing relevant projects that will help improve Profitability, Quality, Productivity, Cost, Efficiency and Customer Delight.

 

Pre-Requisites:

  • Must have one potential Six Sigma project to brought in class.
  • College graduate
  • 2+ years experience in current role

 

Certification Requirements:

  • Completion of the Green Belt classroom training
  • Pass Certification Exams and Checkpoint Exams (80%)
  • Successful Completion of Exercises and Case Studies during training
  • Completion of One Green Belt Six Sigma project

 

Training Agenda:

DEFINE STAGE  (DAY 1)

  1. Six Sigma Overview
    • What is Six Sigma
    • Six Sigma History
    • Six Sigma Approach Y = f(x)
    • Six Sigma Methodology
    • Roles & Responsibilities
  2. The Fundamentals of Six Sigma
    • Defining a Process
    • VOC & CTQ’s
    • Cost of Poor Quality (COPQ)
    • Pareto Analysis (80:20 rule)
  3. Lean Six Sigma Projects
    • Six Sigma Metrics
    • Business Case & Charter
    • Project and Team Selection
  4. Lean Fundamentals
    • Lean & Six Sigma
    • History of Lean
    • The Eight Deadly Muda
    • Five-S (5S)
    • Different Mapping Methods
  5. DEFINE TOLLGATE

 

MEASURE STAGE (DAY 2)

  1. Process Definition
    • Cause & Effect Diagrams
    • Process Mapping Methods/ Value Stream Mapping
    • X-Y Diagram
    • FMEA: Failure Modes & Effects Analysis
  2. Six Sigma Statistics
    • Basic Statistics
    • Descriptive Statistics
    • Distributions & Normality
    • Graphical Analysis
  3. Measurement System Analysis
    • Precision & Accuracy
    • Bias, Linearity & Stability
    • Gage R&R
    • Variable & Attribute MSA
  4. Process Capability
    • Capability Analysis
    • Concept of Stability
    • Attribute & Discrete Capability
    • Monitoring Techniques
  5. MEASURE TOLLGATE
  6. DMADV and Design for Six Sigma Applications

 

ANALYZE STAGE (DAY 3-4)

  1. Patterns of Variation
    • Multi-Vari Analysis
    • Classes of Distributions
  2. Inferential Statistics
    • Understanding Inference
    • Sampling Techniques & Uses
    • Sample Size
    • Central Limit Theorem
  3. Hypothesis Testing
    • Goals of Hypothesis Testing
    • Statistical Significance
    • Risk; Alpha & Beta
    • Types of Hypothesis Test
  4. Hypothesis Testing: Normal Data
    • sample t-tests
    • sample variance
    • One Way ANOVA
  5. Hypothesis Testing: Non-Normal Data
  6. Lean Tools at Analyze Stage
    • Theory of Constraints
    • The Penny Factory
    • Value Stream Mapping
    • Mapping Questions
  7. ANALYZE TOLLGATE
  8. DMADV and Design for Six Sigma Applications

 

IMPROVE STAGE (DAY 4-5)

  1. Simple Linear Regression

    • Correlation

    • Regression Equations

    • Residuals Analysis

  2. Multiple Regression Analysis

    • Confidence Intervals

    • Residuals Analysis

  3. Designed Experiments

    • Experiment Objectives

    • Experimental Methods

    • DOE Design Considerations

  4. Full Factorial Experiments

    • 2k Full Factorial Design

  5. Fractional Factorial Experiments

    • Designs

  6. IMPROVE TOLLGATE

CONTROL STAGE (DAY 5)

  1. Lean Controls

    • 5.1.1 Control Methods for 5S

    • Kanban

    • Poka-Yoke (Mistake Proofing)

  2. Statistical Process Control (SPC)/ Control Charts

  3. Six Sigma Control Plans

    • Cost Benefit Analysis

    • Elements of the Control Plan

    • Elements of the Response Plan

  4. CONTROL TOLLGATE

    • Stages of Deployment

    • Assess-Launch-Planning

    • Implementation

    • Institutionalization

    • Sustaining

  5. Six Sigma Organization and Roles

  6. Pitfalls to Avoid

  7. Peoples, Process, Policy

  8. VISION of Six Sigma

  9. DEPLOYMENT TOLLGATE

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