Introduction

Lean Manufacturing and Six Sigma are two powerful methodologies focused on improving operational efficiency, reducing waste, and increasing the quality of products in manufacturing environments. While Lean focuses on eliminating non-value-added activities (waste), Six Sigma emphasizes reducing variation and defects. Together, these approaches form a complementary system that drives continuous improvement, higher productivity, and greater customer satisfaction.

This comprehensive 5-day training course will provide participants with an in-depth understanding of both Lean Manufacturing and Six Sigma principles. The course will cover key tools and techniques, including Value Stream Mapping, 5S, Kaizen, DMAIC, and Statistical Process Control (SPC), and will teach how to integrate these methodologies for optimal results. Participants will gain hands-on experience with real-world case studies and exercises to develop the skills necessary to implement Lean and Six Sigma strategies within their organizations.

Objectives

By the end of the course, participants will be able to:

1. Understand the core principles of Lean Manufacturing and Six Sigma methodologies.
2. Identify and eliminate waste in manufacturing processes using Lean tools such as Value Stream Mapping, 5S, and Kanban.
3. Apply Six Sigma tools such as DMAIC (Define, Measure, Analyze, Improve, Control) to drive process improvements and reduce defects.
4. Use Statistical Process Control (SPC) to monitor and control processes.
5. Integrate Lean and Six Sigma methodologies for comprehensive process optimization.
6. Understand the roles of Green Belts, Black Belts, and Master Black Belts in Six Sigma projects.
7. Develop strategies for continuous improvement through Kaizen and Root Cause Analysis.
8. Implement data-driven decision making using quality tools and techniques in everyday operations.

Who Should Attend?

This course is ideal for:

• Manufacturing Engineers and Production Managers looking to optimize manufacturing processes.
• Process Improvement Specialists and Six Sigma Practitioners seeking to enhance their knowledge of Lean and Six Sigma techniques.
• Operations Managers and Team Leaders responsible for improving productivity and efficiency within their teams.
• Quality Assurance Professionals seeking to understand the connection between Lean and Six Sigma in quality management.
• Project Managers working on operational excellence and continuous improvement initiatives.
• Students and Graduates aiming to build a career in process improvement, quality control, or manufacturing management.

Course Outline

Day 1: Introduction to Lean Manufacturing and Six Sigma

• Morning Session:

  1. What is Lean Manufacturing? Principles and Goals
  2. The Seven Wastes in Lean: Overproduction, Waiting, Transport, Extra Processing, Inventory, Motion, and Defects
  3. What is Six Sigma? History and Core Concepts
  4. The DMAIC Methodology: Overview and Application
  5. Differences and Synergies Between Lean and Six Sigma

• Afternoon Session:

  1. Value Stream Mapping (VSM): Mapping Current and Future State
  2. The Role of Kaizen in Lean: Continuous Improvement and Employee Involvement
  3. 5S System: Sort, Set in Order, Shine, Standardize, Sustain
  4. Hands-On Exercise: Conducting a Basic Value Stream Mapping Session

Day 2: Lean Tools and Techniques

• Morning Session:

  1. Kanban System: Managing Work and Inventory Through Pull Systems
  2. Just-In-Time (JIT) Production: Delivering the Right Items at the Right Time
  3. Takt Time: Matching Production Rate with Customer Demand
  4. SMED: Single-Minute Exchange of Dies for Faster Changeovers

• Afternoon Session:

  1. Cellular Manufacturing: Creating Efficient Work Cells for Flow Production
  2. Total Productive Maintenance (TPM): Maximizing Equipment Efficiency and Reliability
  3. Root Cause Analysis (RCA): Identifying and Addressing the Underlying Causes of Problems
  4. Hands-On Exercise: Implementing 5S and Kaizen in a Simulated Manufacturing Environment

Day 3: Six Sigma Tools and Methodologies

• Morning Session:

  1. Define Phase (DMAIC): Defining the Problem, Goals, and Scope
  2. Measure Phase (DMAIC): Selecting Key Metrics and Gathering Data
  3. Analyze Phase (DMAIC): Analyzing Data for Root Causes and Process Inefficiencies
  4. Failure Mode Effects Analysis (FMEA): Identifying Potential Failure Points and Prioritizing Actions

• Afternoon Session:

  1. Improve Phase (DMAIC): Developing Solutions and Implementing Process Improvements
  2. Control Phase (DMAIC): Establishing Controls and Monitoring Improvements
  3. Statistical Process Control (SPC): Using Control Charts to Monitor and Improve Processes
  4. Hands-On Exercise: Applying DMAIC to a Manufacturing Process Improvement

Day 4: Integrating Lean and Six Sigma for Optimal Results

• Morning Session:

  1. Integrating Lean and Six Sigma: Creating a Lean Six Sigma Culture in Your Organization
  2. Process Mapping: Understanding and Optimizing Flow Through Both Lean and Six Sigma Tools
  3. Combining Value Stream Mapping (VSM) with DMAIC for End-to-End Process Improvement
  4. Poka-Yoke (Error Proofing): Designing Mistake-Proof Systems

• Afternoon Session:

  1. Creating a Continuous Improvement Strategy: Embedding Lean and Six Sigma into Daily Operations
  2. Standard Work: Establishing Standard Operating Procedures for Process Consistency
  3. Gemba Walks: Observing Work on the Shop Floor to Identify Areas for Improvement
  4. Hands-On Exercise: Developing a Lean Six Sigma Plan for a Process or Product Line

Day 5: Advanced Lean Six Sigma and Future Trends

• Morning Session:

  1. The Role of Green Belts, Black Belts, and Master Black Belts in Lean Six Sigma Projects
  2. Design for Six Sigma (DFSS): Designing Processes and Products with Six Sigma Principles
  3. Lean Six Sigma in Service Industries: Adapting Lean and Six Sigma to Non-Manufacturing Sectors
  4. The Role of Data Analytics, Machine Learning, and AI in Lean Six Sigma

• Afternoon Session:

  1. The Future of Lean and Six Sigma: How Industry 4.0 and Smart Manufacturing Are Shaping Process Improvement
  2. Case Studies: Real-World Applications of Lean Six Sigma in Various Industries
  3. Final Project: Developing a Complete Lean Six Sigma Project Proposal for Process Improvement
  4. Certification Exam and Course Wrap-Up

Certification

Upon successful completion of the course, participants will receive a Certificate of Completion in Lean Manufacturing and Six Sigma. This certification validates the participant’s expertise in both Lean and Six Sigma principles and their ability to apply these methodologies to improve manufacturing processes.

Participants who excel in the course exercises, including their final project, will be awarded a Certification of Excellence in Lean Manufacturing and Six Sigma.