Lean Six Sigma Green Belt Training

Designed for part-time process improvement practitioners to lead project-level teams, analyze baseline metrics, identify root causes, and sustain operational gains.

What we cover

• Module 1: Improvement Methodologies The DMAIC Framework: Overview of Define, Measure, Analyse, Improve, and Control stages and tollgate reviews. Lightweight Improvement Techniques: 3Cs (Concern, Cause, Correct) and the 8Ds (Disciplines) problem-solving method. Iterative Continuous Improvement: Plan-Do-Check-Act (PDCA) Deming cycle and Kaizen philosophy. Design for Six Sigma (DFSS): Developing greenfield processes using DMADV (Define, Measure, Analyze, Design, Verify).
• Module 2: Statistical Process Control (SPC) Basics Statistical Foundations: Population vs. sample, frequency, mean (X), median, mode, variance, and standard deviation (σ). Data Classification: Continuous vs. Discrete (Attribute, Binary) data. Normal Distribution & The Empirical Rule: Bell curves, Z-values, and population distribution thresholds (±1σ,±2σ,±3σ). Process Capability Indices: Potential Capability (Cp) vs. Actual Capability (Cpk) using specification limits (USL/LSL).
• Module 3: Lean Management and Cell Theory The Lean Management Paradigm: Management by targeting, establishing no-blame culture, and eliminating time wasters. Cell Architecture: Cellular manufacturing, U-shaped layouts, and cross-functional team designs. High-Performing Teams (HPTs) & RATs: Forming HPTs, delivering High-Performance Challenges, and deploying Rapid Action Teams (RATs). Visual Management: Visual factory concepts, cell information boards, and separating measures from arbitrary targets. Team Dynamics & Change Psychology: Bruce Tuckman’s model (Forming, Storming, Norming, Performing, Adjourning), the Emotional Cycle of Change (ECOC), and managing resistance.
• Module 4: Risk Management Risk Categorization: Project Risk vs. Business/Enterprise Risk. Risk Management Pipeline: Risk logs, inherent risk, mitigation planning, Early Warning Indicators (EWIs), and residual risk. Failure Mode and Effects Analysis (FMEA): Quantifying Risk Priority Number (RPN=Severity×Occurrence×Detection).
• Module 5: DMAIC for Green Belts – Define & Measure Phases Define Phase Execution: Project establishment, Team Charter creation, Business Case development, and Communications Plans. Measure Phase Execution: Data collection plans, operational definitions, sampling strategies, and check sheets. Measurement System Analysis (MSA): Identifying gauge bias, precision errors, and measurement-induced variance.
• Module 6: SPC Tools and Techniques Data Summarization: Frequency distribution tables and histogram construction. Exploratory Quality Tools: Pareto charts (80/20 rule) and Box & Whisker plots (medians, quartiles, and IQR outliers). Statistical Process Control (SPC) Charts: Center lines, UCL, LCL, and Journal of Quality Technology (JQT) out-of-control rules. Process Efficiency Metrics: Yield, Rolled Throughput Yield (RTY), Defects Per Million Opportunities (DPMO), and Short-Term vs. Long-Term Sigma shift (1.5σ). Correlation & Linear Regression: Scatter plots, Pearson’s correlation coefficient (r), slope (b1), intercept (b0), and trend forecasting.
• Module 7: Analyse Phase Process Decomposition: SIPOC to Level-4 On-the-Ground Instructions (OTGIs). Value Stream Mapping Analysis: Takt time, unit time (UT), cycle time (CT), activity ratio (AR), and the Square Wave (VA vs. NVA time). Root Cause Analysis (RCA): Cause and Effect (Ishikawa / Fishbone diagrams using 6Ms/7Ss), 5-Whys analysis, and "To-Be" VSM design.
• Module 8: Improve Phase Production Smoothing (Heijunka): Process leveling, demand management, Single Piece Flow, and FIFO ordering. Theory of Constraints (TOC): Managing system bottlenecks and Runner, Repeater, Stranger (RRS) activity classification. Solution Selection: Pareto Priority Index (PPI=Savings×ProbabilityCost×Duration), Effort vs. Impact matrices, and Pugh Decision Matrices. Implementation & Standardization: Pilot design, action plans, Standardized Work documentation, and Control Plan drafting.
• Module 9: Control Phase Sustaining Gains: Visual controls, Run Charts, and ongoing SPC governance. Financial Benefit Realization: Net financial savings assessments (gross savings minus implementation and maintenance costs). Project Closure: Post-project review meetings, Follow-On Actions (FOAs), documentation archival, and lessons learned transfer.

Every session is customized to your organization's needs. The final agenda is confirmed with your facilitator before delivery.