Lean Six Sigma Greenbelt

Length

20 weeks
1 session per week
4 hours per session
80 total class hours

Audience

This course is intended for leaders at all levels looking to pursue Lean Six Sigma greenbelt role in this organization.

Description

This course reviews topics that some may have experience with, as well as introducing more advanced tools. Implementation of theory and improvements are achieved in this class through on site projects in conjunction with classroom materials and various simulations based on Six Sigma Green Belt principles.

Detailed Curriculum Topics

(This outline is intended to be a guide for the course and is subject to change without notice at the discretion of the instructor)

Define:

  • Describe the difference between Lean and Six Sigma methodologies
  • PDCA vs. DMAIC
  • Determine the Voice of the Customer
  • Select projects based on strategic importance
  • Defining the Problem
  • Create a project charter
  • Prepare a SIPOC chart (Supplier, Input, Process, Output, and Customer)
  • Identify potential project metrics
  • Prepare a measurement plan
  • Develop a Flowchart
  • Develop a Value Stream Map

Measure/Analyze (Statistical Tools):

  • Define types of data used in descriptive statistics
  • Describe four types of measurement scales (Nominal, Ordinal, Interval, Ratio)
  • Understand methods of gathering data (Manual, Automatic, Data coding)
  • Explain techniques for assuring data accuracy and integrity (random sampling, sequential sampling and stratified sampling)
  • Calculate and interpret the following descriptive statistics
    • Measures of central tendency (mean, median, mode)
    • Measures of dispersion (range, variance, standard deviation)
    • Coefficient of variation (COV)
    • Probability density functions
    • Cumulative distribution functions
  • Create and interpret the following graphical methods
    • Box plots
    • Run chart
    • Scatter diagrams
    • Correlation Coefficient (r)
    • Pattern and trend analysis
    • Histograms
  • Explain the benefit of the Central Limit Theorem
  • Calculate and interpret variable and attribute statistical process control charts.
    • Variable:
      • X and R Chart
      • L X and MR Chart
      • X and S Chart
      • Median Charts
      • Short Run Charts- Differences Chart
    • Attribute:
      • p Chart
      • np Chart
      • c Chart
      • u Chart
  • Waste Identification-Lean Tools
    • The 5S process
    • Conducting GEMBA Waste Walks
  • Measurement Systems Analysis
  • Calculate and interpret the most commonly used distributions
    • Binominal
    • Poisson
    • Normal
    • Student’s t
  • Calculate and interpret short-term and long-term process capabilities.
    • Cp & Cpk
    • Pp & Ppk

Measure/Analyze/Improve/Control (Lean Tools)

  • Criteria for identifying a value-added step.
  • Ishikawa Diagram
  • Value Stream Map Analysis
  • Waste Identification
  • The effect of inventory on cycle time
  • One-Piece flow
  • Set-up Time Reduction
  • Standard Work
  • Visual Controls
  • Poke Yoke
  • Creating a pull system
  • Techniques for smoothing process flow (kanbans, inventory buffers)
  • Explain Kaizen organization and deployment

Improve/Control

  • Root Cause and Corrective Action
    • Determining the cause(s) of the problem
      • Identifying direct, root and contributing causes
        • Affinity diagrams
        • Story boarding
        • Cause and effect analysis
        • Five why’s
        • Pareto analysis
      • Determine corrective actions to be taken
        • Specific
        • Preventative
      • Test actions to be taken
        • Determine metrics to be monitored
        • Conduct trial runs as necessary
        • Preparation and Conducting Audits
      • Analyzing Problems and Implementing Solutions
        • Pro-Con Analysis
        • Effort and Impact Analysis
        • Criteria Selection
        • Cost-Benefit Analysis
  • Project Management Tools
    • Stakeholder Analysis
    • Communication Plan
    • Work Breakdown Structure
    • Gantt Chart
    • Risk Planning
  • Training Techniques
  • Documentation Techniques
  • Standard Work
  • Process Auditing

Review and Wrap-up

  • Review project report/results from each team
  • Presentations and Graduation Ceremony

Employee Application Company Application