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Lean Six Sigma Green Belt Course Outline

Course Content and Outline

Total Estimated Hours: 81.05 *Course includes choice of software: EngineRoom® (included for free), Minitab® (must purchase

separately).

Session 1: Introduction to Lean Six Sigma (4.60 Hours)

 

Introduction

DNA of a Champion
Lean Six Sigma Framework
DMAIC - The Lean Six Sigma Improvement Process
Lean and DMAIC
Thought Process Mapping - Toolset Organizing for Success
Working Relationships Introduction to EngineRoom® / Minitab®
Exercises and Quiz

  •   Higher Standards for Higher Performance

  •   Input Determines Output

  •   Lean Six Sigma Defined

  •   What's In a Name?

  •   The 5 Lean Principles

  •   The 8 Forms of Waste

  •   Success Stories

  •   The Sigma Level

  •   The 99.9% Problem

 
 

Session 2: Define I Starting a Project and Leading Teams (5.05 Hours)

  •   Getting Started - Project Initiation

  •   Project Selection Toolset

  •   Project Charter Toolset

  •   Project Tracking Toolset

  •   Fueling The Improvement Engine

  •   Leading Teams

  •   Developing an Effective Team

Improving Team Development
Leading Change
Leading Change - Continued
Success Factors For Effective Change Management
Stakeholder Analysis - RACI Matrix

Exercises and Quiz

 

Session 3: Define II - Voice of the Customer (6.65 Hours)

  •   Voice Of The Customer

  •   Focus on The Customer

  •   Understanding Customer Requirements

  •   Where to Go For Customer Requirements

  •   Conducting Surveys

  •   More on Surveys

  •   Surveys - Sampling Frame

  •   Structuring Survey Questions

The Degree of Uncertainty in Sampling

Guideline for Margin of Error

Affinity Diagram Toolset
CTQC Tree Diagram Toolset
Operational Definition Toolset

Voice Of The Customer As Specifications
Exercises and Quiz

 
 
 
 

Session 4: Define III - Mapping the Process (5.25 Hours)

  •   Drawing a Process Picture

  •   Process Thinking

  •   The Source of Value

  •   Value Stream Leverage

  •   Process Mapping - Overview

  •   Process Mapping (SIPOC) Toolset

  •   Flow Charts

Value-Added Flow Charts
Spaghetti Charts
Takt Time
Value Stream Mapping Toolset
Define Tollgate - Progress Review

Exercises and Quiz

Session 5: Measure I - Measurements and Basic Statistics (5.75 Hours)

  •   Measurements and Basic Statistics

  •   Business Problem Solving

  •   Basic Statistical Terms

  •   Descriptive and Inferential Statistics

  •   Measurements

  •   Discrete vs. Continuous Measurements

  •   Measurement Subjects

  •   Graphical Summaries

Pareto Chart Toolset
Histogram Toolset
Understanding Variation
Measuring Central Tendency
Quantifying Process Variability

The Normal Distribution
Exercises and Quiz

Session 6: Measure II - Measurement System Analysis (8.55 Hours)

  •   Measurement System Analysis - Introduction

  •   Measurement As A Process

  •   Cause & Effect Matrix Toolset

  •   The Analysis of Measurement Systems

  •   The Requirements of Measurement Systems

  •   Variable MSA - Gauge R & R

  •   MSA - Graphing

  •   Attribute Measurement System Analysis

Calibration of Measurement Systems

Collecting Data
Developing a Sampling Plan
Baseline Performance
Derivative Performance Metrics - Throughput Yield
Derivative Performance Metrics - Rolled Throughput Yield
Calculating the Sigma Level - Toolset

Exercises and Quiz

 
 
 
 
 

Session 7: Measure III - Charting Process Behavior (9.40 Hours)

  •   Introduction - Charting Process Behavior

  •   Trend Chart Toolset

  •   SPC - Introduction and Background

  •   SPC - Introduction to Control Charts

  •   SPC - Control Chart Limits

  •   SPC - More On Control Limits

  •   Implementing SPC

  •   SPC Chart Selection

Rational Subgrouping Toolset
X and Moving Range Charts - Toolset

Attribute Control Chart Toolset
X-bar and R Chart Toolset
Process Capability Toolset
Measure Tollgate - Progress Review

Exercises and Quiz

Session 8: Analyze I - Identifying Potential Root Cause (6.90 Hours)

  •   ANALYZE I - Introduction

  •   Finding The Root Cause

  •   Cause & Effect Diagram Toolset

  •   5-Why, 1-How

  •   A Combination of 5-Why, Pareto, and Trend Charts

Correlation and Regression Analysis

Multiple Regression Toolset
Factors In Determining Sample Size

Estimating Population Mean

Exercises and Quiz

 

Session 9: Analyze II - Hypothesis Testing (11.65 Hours)


Scatter Plot Toolset

  •   ANALYZE II - Introduction

  •   Introduction to Hypothesis Testing

  •   The Process On Trial

  •   The Hypothesis - Accept or Reject?

  •   Types of Error

  •   Hypothesis Testing

  •   Confidence Intervals

  •   Treatment Comparisons - Control Charts

  •   Comparing Two Proportions - Toolset

Comparing Two Means - t-Test Toolset

Comparing Multiple Means - ANOVA Toolset

Confidence Intervals - Least Significant Difference

Hypothesis Testing Learning Lab
Analyze Tollgate - Progress Review

Exercises and Quiz

 
 

Session 10: Improve (11.35 Hours)

  •   Improve

  •   Design for Lean Six Sigma (DFSS)

  •   Benchmarking

  •   Brainstorming

  •   Narrowing Down The List of Ideas

  •   FMEA Toolset

  •   Error-proofing

  •   Prioritizing and Selecting a Solution

  •   The A3 One-Page Report

  •   Continuous Flow Toolset

  •   Balancing Capacity with Demand

  •  

    Session 11: Control (6.05 Hours)

  •   Control

  •   Control Charts Revisited

  •   The Process Control Plan

  •   More On FMEA

  •   Visual Control

  •   5-S Approach

  •   Total Productive Maintenance

  •   TPM Objectives & Benefits

  •   TPM Metrics

Quick Changeover Toolset

Cellular Processing Toolset

Pull System Overview
Pull Scheduling

Kaizen Toolset
Corrective Action Matrix
Piloting a Solution
System Dynamics Toolset
Improve Tollgate - Progress Review

Exercises and Quiz

Best Practices and Lessons Learned

Standardized Work - Documenting Process Changes
Ending the Project
Control Tollgate - Progress Review

Exercises and Quiz
Course Completion
The Lean Six Sigma Journey