Lean Six Sigma - Green Belt Certification

Unit 1: Introduction to Six Sigma

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• History of Quality (Deming, Juran, JIT, Ishikawa, Taguchi, etc.)
• Evolution of Six Sigma: Difference from Traditional Quality Methods
• Defining Six Sigma – philosophy and objectives
• Overview of Six Sigma DMAIC process

Unit 2: Stakeholders

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• Identifying Stakeholders
• Balanced Scorecard: Balancing the needs of all Stakeholders
• Data Collection and Analysis
• Understanding 'Kano' Model
• Benchmarking
• Important Process Performance Metrics
• Financial Measure: Net Present Value (NPV) and Present Value (PV)

Unit 3: Setting up Projects

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• Project Charter
• Charter Negotiation
• Initiating Teams
• Stages of Team Evaluation
• Herzberg's Theory of Motivators and Hygiene Factors
• Handling Conflicts
• Understanding Conflict Intensity
• Management and Leadership Styles
• Understanding Roles Played by People in a Project
• Brainstorming: Nominal Group Technique (NGT)
• Brainstorming: Force Field Analysis
• Multi-Voting
• Project Planning Tools: PERT and CPM
• Project Planning Tool: Crashing
• Creating Affinity Diagrams
• Process Decision Program Charts (PDPC Charts)

Unit 4: Six Sigma Methodology – Define

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• Input: Need for Six Sigma Project
• Input: Executive Management Sponsorship
• Input: Core Team Identified
• Tools: Organisational Hierarchy
• Creating High Level Process Maps
• Understanding Process Map Symbols
• Creating Pareto Charts
• Steps in Pareto Analysis
• Establishing Metrics
• Defining Problem Statement
• Outputs: Roles and Responsibilities

Unit 5: Six Sigma Methodology – Measure

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• Objectives of Measure Phase
• Inputs: The Outputs of the Define Phase
• Data Collection Tools and Techniques
• Using Measurement Scales
• Validation Techniques
• Important Characteristics of Measurement Systems
• Probability Distributions
• Data Mining
• Using Run Charts
• Detailed Process Maps and Pareto Charts
• Stakeholder Tools
• Process Costs
• Outputs: Well-Defined Processes
• Measurement Systems
• Outputs: Baseline Process Capability
• Process Capability Impacting Critical to Quality
• Cost of Poor Quality (COPQ)

Unit 6: Six Sigma Methodology – Analyse

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• Objectives of the Analyse Phase
• Inputs: The Outputs of the Measure Phase
• Tools: Ishikawa Diagram (Cause and Effect or Fishbone Diagram)
• Hypothesis Testing
• Process Capability Study
• Improving Process Capability
• Outputs: Important causes of defects
• Outputs: Special and common causes of variation
• Defective Parts per Million (DPMO) and Sigma Level

Unit 7: Six Sigma Methodology – Improve

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• Objectives of Improve Phase
• Inputs: Outputs of the Analyse Phase
• Tools: Return on Investment (ROI)
• Tools: Solution Design Matrix
• Design of Experiments: Important Terms and Concepts
• Benefits of the Design of Experiments
• Taguchi Robustness Concepts
• Response Surface methodology
• Project Planning and Management Tools
• Prototypes
• Outputs: Cost and Benefit of Different Solutions
• Selecting a Solution to Implement
• Implementation Plan

Unit 8: Six Sigma Methodology – Control

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• Objectives of Control Phase
• Inputs – Outputs of the Improve Phase
• Tools: Control Plan
• Lean Enterprise
• 5S
• Kaizen
• Kanban
• Total Productive Maintenance (TPM)
• Measurement System Re-analysis
• Implemented Solutions
• Revised Measurement System
• Control Plan for Sustaining Benefits
• Improved Process Capability
• Lessons Learned

Unit 9: Lean Six Sigma

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• Lean is Speed
• Value Stream Map
• Total Supply Chain
• Pull System - Kanban
• Lean Six Sigma Logistics
• Standard Operations
• Operator Work Instructions
• Cycle Time Reduction and Takt Time

Unit 10: Case Study

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