Lean Six Sigma Green Belt

Introduction

American company Motorola developed a new concept of quality management process in 1986. Over the years, it has been refined and polished into a sound theory of principles and methods, aimed at business transformation through a clearly defined process. This finished product is Six Sigma.

Overview

Six Sigma Green Belt provides the necessary skills to successfully apply a field-proven methodology that helps process improvement. Moreover, it positively influences data-based decision making in solving problems and completing projects within predetermined deadlines.

Goals of Six Sigma

The concept of Six Sigma has a simple goal – delivering near-perfect goods and services for business transformation for optimal customer satisfaction (CX). Goals are achieved through a two-pronged approach:

• Identification of the problem
• Solving the problem

Objective

Upon completion of this program, participants should be able to:

• Reduction in process cycle time
• Reduction of scrap generated by a process
• Increasing customer satisfaction
• Reduction in the number of factory defects
• Reduction or elimination of costly reworks

Key content

Introduction

• History of Six Sigma
• Six Sigma Belts Hierarchy
• What is Six Sigma Green Belts?
• Six Sigma link with company vision, objective, measurement and target (ISO 9001:2015)

7 key Six Sigma principles

• Always focus on the customer
• Understand how work really happens
• Make your processes flow smoothly
• Reduce waste and concentrate on value
• Stop defects through removing variation
• Get buy-in from the team through collaboration
• Make your efforts systematic and scientific

The Six Sigma methodology

DMAIC: Define, Measure, Analyse, Improve, Control – applied in the manufacturing of a product or delivery of a service.
DMADV: Define, Measure, Analyse, Design, Validate

Six Sigma techniques

• Brainstorming
• Root Cause Analysis / The 5 Whys
• Voice of the Customer
• The 5S System
• Kaizen (Continuous Improvement)
• Benchmarking
• Value Stream Mapping

The Six Sigma process of business transformation

1. Define Phase

• The Basics of Six Sigma
• The Fundamentals of Six Sigma
• Selecting Lean Six Sigma Projects
• The Lean Enterprise
  • ​Six Sigma Tools:
    • Affinity Diagram
    • Failure Mode and Effect Analysis (FMEA)
    • Process Mapping
    • Value Added Flow Analysis
    • Value Stream Mapping
    • 7 Wastes
    • Take Time
    • Prioritization Matrix
    • The 5Ss
    • PDSA

2. Measure Phase

• Process Definition
• Six Sigma Statistics
• Measurement System Analysis
• Process Capability
  • Six Sigma Tools:
    • Histogram
    • Pareto Chart
    • Trend Chart

3. Analyse Phase

• Patterns of Variation
• Inferential Statistics
• Hypothesis Testing
• Hypothesis Testing with Normal Data
• Hypothesis Testing with Non-Normal Data
  • Six Sigma Tools:
    • The 5 Whys
    • Ishikawa Diagram
    • Regression Analysis

4. Improve Phase

• Simple Linear Regression
• Multiple Regression Analysis
  • Six sigma tools:
    • A3
    • Kaizen
    • Hoshin Kanri
    • Kanban Pull System
    • Poka Yoke
    • Heijunka Box
    • Single Minute Exchange of Die (SMED)
    • Distribution, logistics, delivery (JIT)

5. Control Phase

• Lean Controls
• Statistical Process Control (SPC)
• Six Sigma Control Plans
  • Six Sigma Tools:
    • Statistical Process Control (SPC
    • Standardized Work