Lean Six Sigma Green Belt - United States

Lean Six Sigma Green Belt Course Outline

This Six Sigma Green Belt training course will explore the following areas:

Module 1: Introduction to Lean 6 Sigma

• What is Lean 6 Sigma?
  • Two Parts of Lean 6 Sigma
  • Focus of Lean
  • Lean Temple
  • Focus of Six Sigma
  • Making Customers Happy
  • How they Complement Each Other?
  • Key Principles of Lean 6 Sigma
• Lean 6 Sigma Belts
  • TKA Lean 6 Sigma Belt Structure
  • Training Roadmap
  • Role of the Yellow Belt
  • L6S Support Network
• Processes
  • Different Ways of Looking at Process Improvement
  • What is a Process?
  • Process Concepts
  • Types of Process
  • Comparing Process Types
• Customers, Value, and Waste
  • What are Customers?
  • Who Wants the Outputs?
  • Tension Between the VOB and VOC
  • What Do We Mean by Value?
  • Path to Value
  • Dealing with Values
  • Muda (Waste)
  • Seven Wastes (Muda) of Lean
  • Types of Demand
  • Case Study Exercise
• Key Metrics

Module 2: DMAIC Cycle

• What is DMAIC?
• Define
  • Common Tools for Define Phase
  • Gemba Tools
  • Process Stapling
• Measure
  • Common Tools for Measure Phase
  • Spaghetti (Movement/Transportation) Diagrams
  • Measure Tool: Measles Charts
• Analyse
  • Common Tools for Analyse Phase
• Improve
  • Common Tools for Improve Phase
• Control
  • Common Tools for Control Phase

Module 3: Yellow Belt Tools and Techniques

• Lean Triad
  • 5s
  • Poka Yoke
  • SMED
• Voice of the Customer (and CTQ’s)
  • Customer Chains
  • 4 Steps of VOC
  • Affinity Diagrams
  • Kano Diagrams
  • CTQs and Requirements
• SIPOC
  • What is a SIPOC?
  • Example SIPOC
  • CSandF Web Fulfilment SIPOC
  • Creating a SIPOC
  • Top Tips – SIPOC
• Value Stream Analysis
  • Value Stream Terminology 
  • Process Maps
  • Aim of Value Stream Mapping
  • Swim Lanes
  • Typical Process Map Contents
  • Value Stream Maps
  • Headache Tablets: Value Stream Mapping
• Heijunka
  • Heijunka in a Nutshell
  • Single Piece Flow
  • Pull
  • Kanban
  • Three-Bin System
  • Andon
• Variation and SPC
  • Statistical Process Control (SPC)
  • Two Types of Process Variation
  • Red Bead Experiment
  • Standard Deviation (SD)
  • Understanding Control Charts
• Defects and Process Capability
  • Conversion Table
  • Process Capability
  • Identifying Process Efficiency
• Process Efficiency
  • Identifying Process Efficiency
  • Key DPMO Terms
• Identifying the Root Cause(s)
  • 5 Whys
  • Fishbone Diagram
• Solving Problems
  • Problem Solving Framework
  • Prioritisation Tools
  • Tools and Techniques to Generate Needed Solutions
• Introduction to Kaizen
  • Kaizen in a Nutshell
  • Kaizen in a Business Setting
• Lean Teams
  • Introduction to Lean Team
  • Managing Progress and Demonstrating Control

Module 4: Introduction to DMAIC and DMADV 

• DMAIC Vs DMADV 

Module 5: Variation

• What is Variation?
• Variation Tools
• Variation Terminology
• Two Types of Process Variation
• Averages

Module 6: Bar Charts and Histograms

• Bar Charts
• Histograms
• How Bar Charts and Histograms Can Be Used?
• Pareto Charts

Module 7: Basic Distribution and the Bell Curve

• Bell Curve
• Distribution Curves
• Normal Bell Curve
• Empirical Rule
• What Does the Empirical Rule Mean?
• Testing for a Normal Distribution
• Standard Deviation
• Calculating Standard Deviation
• Estimating Standard Deviation
• Process Capability
• CPK
• What Value is Acceptable and NOT Acceptable?

Module 8: Control Charts

• About Control Charts
• Using Sigma to Identify if Process is in Control
• Journal of Quality Technology Zones
• Data Classification
• Qualitative and Quantitative Data
• Why is the Class of Data Important?
• Run Charts

Module 9: Defects and Process Sigma Levels

• Ways of Measuring Process Efficiency
• Yield
• Key DPMO Terms
• Methodology for Calculating DPMO
• Process Sigma
• Converting DPMO to Process Sigma and Yield
• Short Terms and Long Term Process Sigma
• Expressing Process Efficiency
• Converting DPMO to Process Sigma and Yield

Module 10: Scatter Diagrams, Correlation, and Regression

• Scatter Diagrams
• Regression
• Forecasting
• Correlation Coefficient
• Scatter Diagrams and Regression Analysis

Module 11: Green Belt Lean Techniques

• Pull
• Requirements for Effective Pull
• Kanban
• Three-Bin System
• Kanban Operation Rules
• Andon
• Heijunka
• Process Levelling
• Resource Scheduling
• Runner, Repeater, and Stranger
• Process Levelling in the Office
• Lean Office

Module 12: Value Stream Mapping

• Process Map Levels
• On the Ground Instructions (OTGIs)
• Value Stream Maps
• What is a Value Stream?
• Investigating and Understanding the Process
• Headache Tablets
• Creating a VSM
• Process Boxes
• Useful VSM Metrics
• VSM Metrics
• Square Wave
• Kaizen Burst
• Creating an Improved Process