Training Category: Six Sigma Certifications

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Duration: Five Days

Note: This course is delivered in a customized format only to private company or groups in a virtual or onsite environment.

About the Course:

This course is fast-paced and project focused. It provides everything needed to complete a Lean Six Sigma Green Belt project. It assumes that the participant will bring an assigned process improvement project to the training, or at least an area of your work environment that might become a project. If a project has not been assigned, you will be assigned a case study from which you will build a model when a project is assigned.

Course Objectives:

This course allows the participant to learn the basic tools and concepts of Lean and Six Sigma and immediately apply them to an assigned project.

Target Audience:

No pre-assessment is given; the course assumes no prior knowledge in the tools, activities, concepts, and statistics of process improvement.

What’s Included:

A workbook is available that closely follows the training material, which can be printed or used electronically. This workbook emphasizes the key, need-to-know material of process improvement. It contains supporting exercises with answers, as well as step-by-step commands for Minitab graphs and statistical tests.

While this is a live, instructor-led course, there are additional links to various videos that reinforce the core material. All exercises are meant to reinforce the presentations and allow for direct application of the tools and activities to an assigned project. By the end of the course the participant will be quite far ahead in the completion of a Green Belt Certification project.

A 50 question, multiple choice, open materials assessment is given after the training is completed and is part of the certification process.

Certification:

The participant has the opportunity to continue working on their assigned project, complete the project, and earn a Green Belt Certification based on project completion. The requirements for this certification will be covered as part of the course and any completed project requirements will be placed in the project documentation template.

Couse Content:

Module 1

  • Overview of Six Sigma
  • Overview of Lean
  • Thinking modes for process improvement
  • Impact of Variation
  • Cost of Poor Quality
  • Sources of variation
  • DMAIC phases and key deliverables
  • DMAIC phase summary
  • Approach to Problem Solving
  • Introduction to the Eight Wastes
  • Variation and metrics video example
  • LSS Deployment topics
  • Lean Six Sigma Overview

Module 2

  • The Thinking Modes of Process Improvement
  • Process thinking
  • Variation thinking
  • Metrics thinking
  • Requirements thinking
  • Root cause thinking
  • Systems thinking:
  • Measurement thinking:
  • Equipment performance thinking

Module 3

  • Steps to project selection and chartering
  • Project definition, the Basics
  • Project charter elements
  • Project charter format
  • Charter element exercise

Module 4

  • Team development
  • Possible team ground rules
  • Stakeholder analysis
  • Communications plan
  • Risk analysis
  • RACI matrix
  • MGPP
  • Action Log
  • Example agenda
  • Review and actions

Module 5

  • Internal versus External customers
  • Converting verbatim VoC into CTQs
  • The Kano Model
  • Project VoC actions
  • Characteristics of good customer requirements
  • Current customer-related metrics

Module 6

  • Project Management Tools
  • Lean Six Sigma deployment roles
  • Lean Six Sigma deployment success factors
  • Lean Six Sigma deployment metrics

Module 7

  • Types of process maps
  • Detailed process map symbology
  • Process map questions
  • Methods to start or develop process maps
  • SIPOC map
  • Steps for building a Process Variables Map
  • Process Variables Map exercise
  • Process Variables Map review
  • Process map type exercise

Module 8

  • Steps for building a cause-and-effect matrix
  • Cause and effect matrix exercise
  • Cause and effect matrix review

Module 9

  • Steps for building a FMEA
  • Severity scale example
  • Combined SOD scale example
  • Other Severity and Occurrence scale examples
  • FMEA overview questions
  • FMEA exercise

Module 10

  • The eight wastes
  • Actions for each waste
  • Waste Walk
  • The three Ms of Lean
  • Toast Kaizen worksheet

Module 11

  • Purpose of data collection
  • Types of data
  • Data Types exercise
  • Data Collection Plan element definitions
  • Data Collection Plan element notes
  • Project metrics
  • Data collection sheet exercise

Module 12

  • Data Analysis Flow summary
  • Data Analysis Flow graphical flow
  • Step 1: Look at the data
  • Step 2: Descriptive statistics
  • Step 3: Check for process stability
  • Step 4: Test for normality
  • Step 5: Perform a process capability analysis
  • Step 6: Graphical analysis
  • Step 7: Statistical analysis
  • Step 8: Follow up analysis
  • Data analysis exercise

Module 13

  • Descriptive statistics –central tendency
  • Descriptive statistics
  • Spread or dispersion
  • Introduction to of graphs
  • Types of graphs
  • Graph versus data type exercise
  • Graph drawing exercise

Module 14

  • Minitab worksheet arrangement
  • File and Edit pulldown menus
  • Data and Calc pulldown menus
  • Stat pulldown menu
  • Graph pulldown menus
  • View, Help, and Assistant pulldown menus
  • Command entry overview

Module 15

  • Capability for discrete count data
  • Definition of defect versus defective
  • Definition of opportunity
  • Calculating Defects Per Million Opportunities (DPMO)
  • Sigma Quality Level Table
  • Capability for continuous data
  • Strategies for improving process capability
  • C and P ratios
  • Minitab process capability analysis output
  • Minitab process capability combined graph
  • Capability assessment exercise
  • Capability analysis review and action

Module 16

  • Control chart elements
  • Types of variation
  • Control chart signals
  • Control chart selection tree
  • Individual and Moving Range chart
  • Control chart staging
  • X-bar and R chart
  • Appropriate action
  • Control charts –label for project Y
  • Exercise –evaluate signals
  • Exercise –capability versus control
  • Exercise –scenario evaluation
  • ImR control chart forms

Module 17

  • MSA component tree
  • Measurement system terminology
  • Minitab Gage R&R setup
  • Gage run chart
  • Minitab Gage R&R graphical analysis
  • Minitab Gage R&R statistical analysis
  • Gage R&R Example
  • Minitab Attribute R&R setup
  • Minitab Attribute R&R analysis
  • Measurement System Analysis review questions
  • Project MSA Action

Module 18

  • Paper helicopter exercise
  • Cheese cracker production process

Module 19

  • Multi-vari study definitions
  • Multi-vari study examples
  • Data collection sheet for multi-vari studies
  • Multi-vari study data analysis exercise
  • Multi-vari project exercise

Module 20

  • Root Cause Analysis

Module 21

  • Hypothesis test terminology
  • Comparative analysis methods
  • Ho versus Ha
  • Types of errors
  • The process of hypothesis testing
  • Types of hypothesis tests
  • The paths of data analysis and hypothesis testing
  • Hypothesis test selection flow
  • Hypothesis test reference table
  • Exercise: test selection
  • Exercise: project application

Module 22

  • Hypothesis Testing

Module 23

  • Path 1: tests for differences
  • Types of tests for differences
  • Minitab: 1 Sample t-Test
  • Minitab: 2 Sample t-Test
  • Minitab: 2 Variance test
  • Minitab: Test for Equal Variances
  • Minitab: Analysis of Variance (ANOVA)

Module 24

  • Factors that impact sample size
  • Technical notes: impact of factors
  • Minitab: power and sample size calculator
  • Example
  • Example
  • Population average and proportion sample sizes

Module 25

  • Chi-square data arrangement
  • Minitab: chi-square test setup
  • Chi-square test interpretation

Module 26

  • Path 3: Correlation and Regression
  • Minitab: correlation
  • Minitab: regression
  • Minitab: residual analysis
  • Regression analysis exercise
  • Correlation and regression review

Module 27

  • Background
  • Exercise instructions
  • Suggested tests and evaluation

Module 28

  • DoE language and definitions
  • Steps for designing an experiment
  • DoE example -MPG
  • DoE setup in Minitab
  • Analyzing an experiment in Minitab
  • DoE graphical analysis
  • DoE exercise using a simulator
  • Designing your own experiment

Module 29

  • Lean Fundamentals
  • 5S
  • Establish flow
  • Establish pull
  • Mistake-proofing
  • Changeover time reduction
  • Replenishment systems
  • Visual Management
  • Lean Improvements
  • Total Productive Maintenance

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