Introduction:

Lean Six Sigma is a proven methodology that combines two powerful concepts—Lean and Six Sigma—to improve processes, reduce waste, and enhance productivity. The Lean Six Sigma Green Belt Certification Training Course is designed for professionals who are responsible for improving process quality and driving change within their organization. This course provides an in-depth understanding of the Lean Six Sigma framework, tools, and techniques necessary for identifying and solving problems in business processes. Upon completion, participants will be equipped with the skills and certification to lead or participate in process improvement initiatives.

Course Objectives:

By the end of this course, participants will:

1. Understand the key principles and concepts of Lean Six Sigma and how they integrate for process improvement.
2. Learn the DMAIC (Define, Measure, Analyze, Improve, Control) methodology and its application in process improvement.
3. Be able to use various Lean and Six Sigma tools (e.g., value stream mapping, control charts, root cause analysis) to identify inefficiencies and implement sustainable solutions.
4. Develop the skills to lead process improvement teams and contribute to data-driven decision-making.
5. Learn how to apply Lean Six Sigma techniques to real-world business problems to improve productivity, reduce costs, and enhance customer satisfaction.
6. Achieve Green Belt certification, enabling participation and leadership in Lean Six Sigma projects.

Who Should Attend?

This course is ideal for:

• Managers and team leaders looking to improve operational efficiency and reduce waste.
• Process owners and employees involved in process improvement efforts.
• Project managers who need a structured approach to problem-solving.
• Quality assurance professionals and anyone working in process optimization roles.
• Professionals seeking to gain Lean Six Sigma Green Belt certification and enhance their career prospects.

Day-by-Day Outline:

Day 1: Introduction to Lean Six Sigma and DMAIC Methodology

• Overview of Lean Six Sigma:
  • History and evolution of Lean and Six Sigma
  • Key concepts of Lean (waste elimination, value stream mapping, etc.)
  • Key concepts of Six Sigma (statistical analysis, defect reduction, etc.)
  • The importance of customer value and continuous improvement
• The DMAIC Methodology:
  • Define: Understanding the project goals and scope
  • Measure: Identifying the critical metrics and data collection methods
  • Analyze: Data analysis techniques for identifying root causes
  • Improve: Designing and implementing solutions to improve processes
  • Control: Maintaining improvements and ensuring long-term sustainability
• The Role of Green Belts in Lean Six Sigma Projects:
  • Green Belt vs. Black Belt roles
  • Leading and supporting process improvement projects
  • Key responsibilities and skills required for a Green Belt

Day 2: Define Phase and Voice of the Customer

• Defining the Problem:
  • Understanding the problem-solving process and identifying project goals
  • Stakeholder analysis and project charter development
  • Setting clear objectives aligned with customer needs and business goals
• Voice of the Customer (VOC):
  • Importance of capturing customer feedback and requirements
  • Tools for VOC collection (surveys, interviews, focus groups, etc.)
  • Translating VOC into critical to quality (CTQ) metrics
• Project Selection and Scope:
  • Selecting appropriate projects for Lean Six Sigma
  • Defining the scope and boundaries of the project
  • Avoiding scope creep and managing stakeholder expectations

Day 3: Measure Phase – Data Collection and Process Mapping

• Measuring the Current State:
  • Introduction to data types and data collection methods
  • Key performance indicators (KPIs) for process measurement
  • Data collection techniques (surveys, time studies, observation, etc.)
• Process Mapping Tools:
  • Value Stream Mapping: Identifying value and waste in a process
  • Process Flowcharts: Visualizing the current process steps
  • SIPOC Diagrams (Suppliers, Inputs, Process, Outputs, Customers)
• Introduction to Process Metrics:
  • Process capability and performance metrics (CP, CPK, DPMO, etc.)
  • Understanding the normal distribution and its role in process performance
  • Identifying critical-to-quality (CTQ) parameters
• Statistical Tools for Data Analysis:
  • Introduction to basic statistical concepts (mean, median, standard deviation, etc.)
  • Overview of control charts and process behavior analysis

Day 4: Analyze Phase – Root Cause Analysis and Hypothesis Testing

• Root Cause Analysis (RCA):
  • Techniques for identifying the root causes of process problems (5 Whys, Fishbone diagram)
  • Using Pareto analysis to identify key issues
• Hypothesis Testing:
  • Introduction to hypothesis testing and statistical significance
  • Using t-tests and chi-square tests for analyzing process data
  • Understanding confidence intervals and p-values
• Data Analysis and Pattern Recognition:
  • Identifying process patterns and trends using statistical tools
  • Correlation analysis and regression analysis
  • Visual tools for analysis (histograms, scatter plots, box plots)
• Hands-On Exercise:
  • Participants will work on analyzing data from a case study, applying root cause analysis, and using hypothesis testing to validate their findings.

Day 5: Improve Phase – Solution Design and Implementation

• Designing Solutions:
  • Brainstorming and prioritizing potential solutions using tools like brainstorming, affinity diagrams, and Pareto analysis
  • Developing and testing potential solutions (pilot testing, simulations)
  • Creating an implementation plan for solutions
• Improvement Tools and Techniques:
  • Introduction to Lean tools (Kaizen, 5S, Kanban, Poka-yoke)
  • Introduction to Six Sigma tools (design of experiments, process optimization)
  • Using Failure Modes and Effects Analysis (FMEA) to assess risks
• Control Phase – Sustaining Improvements:
  • Creating control plans and documentation
  • Using control charts to monitor process performance
  • Ensuring long-term sustainability of improvements
• Green Belt Project Completion:
  • Finalizing the Lean Six Sigma project with a presentation of solutions and results
  • Key lessons learned from the project
• Review and Certification Exam:
  • Review of key concepts from the course
  • Final exam covering all topics in the Lean Six Sigma Green Belt syllabus
  • Certification requirements and process for obtaining Lean Six Sigma Green Belt certification.