Lean Six Sigma Green Belt Certification Program Outline
Three two-day sessions with facilitated project work during and between sessions.
Session One
Lean Six Sigma principles, project selection, complete the “Define” and “Measure” phases, and start the “Analyze” phase of DMAIC.
Day 1
I. Introduction and Expectations
- What are Lean and Six Sigma?
- Definitions
- Evolution of Quality Improvement
- Advantages and uses of DMAIC problem solving and Kaizen events
II. Process Improvement Examples
- Case Studies
III. Overview of Problem Solving and Process Improvement Strategies
- Step 1: “Define” tools and Selecting and Supporting Successful Improvement Projects
- Step 2: “Measure” Tools and Making the Current Process Visible and Determining Baseline Data
- Step 3: “Analyze: Tools and Identifying Waste and Inefficiencies
- Step 4: “Improve” tools and Designing Improvements
- Step 5: “Control” tools and Testing Improvement Ideas
- Step 6: “Replicate” Tools and Implementing Improvements
IV. Selecting and Supporting Successful Improvement Projects
- Scope and Charter
- Go/ No-Go checklist
- SIPOC
- Collecting and analyzing baseline data
- Determining who should be involved and roles
- Level Setting, Operational Definitions and Ground Rules
V. Making the Invisible Visible
- Process Mapping
- Value streams
- Swim Lanes
- Cycle time vs. Lead time
VI. Begin Classroom Case Study
End of Day 1
Day 2
I. Create “Define” tools
- SIPOC
- Business Process Map
II. Identify the 8 Common Causes of Waste
- Transportation
- Inventory
- Motion
- Waiting
- Over producing
- Over processing
- Delays
- Underutilization
III. Identify Non Value-added Activities
IV. Customer Focus
V. Data-Based Decision Making
- Meaningful Measures
- Tampering
- Doing the wrong thing better and better
VII. Complete Selection of Individual Green Belt Projects
- Process Selection
- Scope
- Customer Needs / Critical to Quality
- Goals and Measures
VIII. Developing Data Collection Plans
- Assignments for customer feedback and peer reviews of data and tools
- Elevator Speech
End of Day 2
2-3 WEEKS TO WORK ON GREEN BELT PROJECT
- Complete data collection plan, review SIPOC and process map with team, and prepare to teach assigned tool.
- Remote coaching and guidance by instructor
Session Two
Finish learning “Analyze” on baseline data collected. Learn “Improve” and “Control” phases of the DMAIC process. Review progress and work on project
Day 3
I. Tool Time Teach-backs
- Run Chart
- Control Chart
- Histogram
- Pareto Chart
- Fishbone Diagram
- Affinity Diagram
- Force Field Analysis
- Nominal Group technique
II. Continue Development of Individual Green Belt Projects
III. Continue Class Room Case Study
- Common Vision tools
- Looking for Clues
- Idea generation and prioritization tools
- Risk analysis
- Clean sheet re-design
IV. Poka Yoke
- Examples
- Creating a mistake-proof form exercise
V. Continue Design of Individual Green Belt Projects
End of Day 3
Day 4
I. Review Progress Of Lean Belt Projects
- Data collection and analysis
- Scope and goals adjustment
- Next Steps
II. Change Management
- Reaching consensus
- Overcoming resistance
- Creating Buy- In
III. Implementation Strategies
- Action Registers
- Study and phase in pilot solutions
- Time Trees
- Gantt Charts
- Project Management
IV. Visual Management and Score Cards
V. 5S + Safety
VI. Complete Class Room Case Study
VII. Classroom time for Individual Green Belt Project Work
VIII. Homework and Project Completion Assignments
End of Day 4
2-3 WEEKS TO WORK ON GREEN BELT PROJECT
- Refine improvements and implementation plans.
- Coaching and guidance off site
Session Three
Learn how to facilitate other people’s projects, drive change, and incorporate Lean into culture. Time to fine tune project presentations and feedback.
Day 5
I. Facilitating Projects that are not your own
- Working with other teams
- Forming, Storming Norming, Performing, Adjourning
- Change Management
- Creating Business Case
II. Facilitating other people’s projects Case Study
- Map process
- ID waste
- Countermeasures
- Clean-Sheet Redesign
III. Creating a Lean Culture
- 8 steps from investigation to imbedded in DNA
- Top down commitment
- Bottom Up Support
- Employee Development
- Anchoring Lean in the policies and practices of the organization
IV. Classroom time to finalize project presentation
End of Day 5
Day 6
I. Green Belt Project Presentations:
- 20-minute review of data collected, analysis, goals, tools used, projected results, implementation strategies for each participant
- Question and comments from participants
- Final Feedback from Instructor
II. Awarding of Green Belts when criteria completed
End of Day 6