- Demonstrate an understanding of where Lean Six Sigma came from and how it applies to your business
- Understand and apply the DMAIC approach
- Be able to write a great problem statement for a team based department-wide problem
- Develop an understanding of process theory
- Consider and utilise different ways of developing an understanding from a customer perspective. Often with Green Belts this can be an internal or external customer
- Be able to identify the classic lean wastes
- Use value stream mapping to identify value-added processes and steps or processes that produce waste, including excess inventory, unused space, test, inspection, rework, transportation and storage.
- Metrics and measurements is a huge category of learning and at Green belt you’ll need to understand how to generate and interpret Pareto Charts, Histograms, Scatter Plots and box-and-whisker plots
- Cause and Effect diagram and/or 5 Whys are the basic Yellow belt requirement here – there will also be some of the basic graphical tools to help take us from hunch to fact
- Use FMEA to evaluate a process or product and determine what might cause it to fail and the effects that failure could have. Identify and use scale criteria, calculate the risk priority number (RPN), and analyze the results.
- Understand the concept and application of error proofing
- Work study, standard operating procedures and work standards
- Visual Cards (Kanban), Signal Alerts (Andon) and Display Boards are one of the key techniques for making work visible
- Project Management
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- Understanding of Lean, Six Sigma & Theory of Constraints
- Understanding of value chain, flow, and perfection.
- End users, process owners, and stakeholders
- Team types, stages of team development and communication tools
- Describe how suitable projects are identified and selected.
- Project Scoping
- Project Charter
- Project Metrics
- Quality Function Deployment (QFD)
- SIPOC model
- Data Collection Plan
- Voice of the Customer
- 8 Wastes
- Value stream mapping to identify value-added processes and steps or processes that produce waste.
- Process Performance metrics DPU, RTY, CoPD and DPMO
- Control Charts, Paretos, Histograms & Scatter Plots
- Basic probability concepts
- Central limit theorem
- Statistical distributions
- Cause & Effect
- 5 Why
- Flow - batching vs single piece
- Failure mode and effects analysis (FMEA)
- Value Adding Analyses
- Cycle time reduction
- Project Risk Analysis
- Root Cause Analysis
- Error Proofing
- 5S
- Visual Management
- Kanban Cards
- Standard Operating Procedures
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- Hands on examples.
- Build a project charter
- TLS Model.
- Team memebers, types, communication styles (Exercise)
- Normal Distribution & Process Capability.
- Practical demonstrations of process theory
- The Paper Clip Factory (Exercise).
- Core lean, Six Sigma and TOC principles.
- Customer perspective on value.
- Quality function deployment (QFD) to translate customer requirements into product/service features, performance measures,or opportunities for improvement.
- Value Vs Non Value Vs Necessary Non Value
- Waste identification.
- Process Mapping (Exercise).
- The Value Stream.
- The Current State Map.
- Value Stream Analysis.
- The Future state map.
- Lean Building Blocks.
- Workplace Organisation – 5S.
- 5S (Exercise).
- Visual Management.
- Error Proofing (Poke Yoke)
- Employee Involvement & Continuous Improvement.
- Quality at the source.
- Thinking Lean (Exercise).
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