By the end of this course, delegates will be able to:

• A complete coverage of all Lean methods and technique
• More detailed and advanced understanding of the DMAIC and DMADV process
• Thorough understanding of measurement and key data analysis technique aimed at understanding process performance, problem solving and root cause analysis
• Working knowledge of the Failure Modes and Effects Analysis Technique
• The “Wrestling with Jellyfish” methodology for dealing with intangible problems
• Be able to successfully execute and implement projects using each of the methodologies covered in the course and be able to correctly decide which the most appropriate methodology for each situation is.

This course introduces participants to all of the core concepts underpinning the Lean Six Sigma approach to implementing a business improvement oriented culture and systems in organizations, and how these are used to improve customer satisfaction, process performance, and enhance competitive advantage and business results. In Lean Six Sigma organizations, it is the Green Belts who lead and contribute to the majority of improvement teams undertaking the improvement projects that will make continuous improvement through Lean Six Sigma a key element of achieving and maintaining operational excellence. The course will provide participants the level of knowledge and skill required to achieve accreditation at the Green Belt level.

This interactive Training will be highly interactive, with opportunities to advance your opinions and ideas and will include:

• Lectures
• Workshop & Work Presentation
• Case Studies and Practical Exercise
• Videos and General Discussions

   Introduction and Foundation Concepts

• Introduction to Lean Six Sigma
• Roles and Responsibilities
• Linking Improvement to Strategy
• Selecting the Right Projects

The Define Phase Detail

• Define Phase Overview       
• Identifying Opportunities
• The Three Voices of Define
• The Voice of the Business
• The Voice of the Customer
• The Voice of the Process

The Measure Phase Detail

• Determining What to Measure
• The Y=f(x) Relationship
• The Generic Process Measurement Scorecard
• Leading and Lag Indicators
• Monitoring and Diagnostic Measures
• Critical to Quality Tree
• Measurement Assessment Tree
• Developing Operational Definitions
• Measurement System Analysis

The Measure Phase Detail (continued)

• Understanding the Measures
• The Funnel Experiment/Simulation
• Normalization
• Populations and Samples
• Sampling and Bias
• Types of Data
• Collecting and Displaying Data
• Check sheets and Pareto Charts
• The Pareto Principle
• Dot plots, Histograms & Run Charts
• Developing Descriptive Measures of Data
• Measures of Location – Mean/Median/Mode
• Measure of Spread – Range, Standard Deviation, IQR
• Box Plots and test for Normality

Understanding Variation

• Common and Special Causes
• The Normal Distribution
• Quantifying Process Performance
• The Control Chart Concept
• Stable and Unstable Processes
• Process Improvement through Variation Reduction
• The She-wart Tests
• Introduction to Statistical Process Control

Assessing Process Performance

• Process Capability
• The Hidden Factory
• Yield, First Pass Yield and Final Throughput Yield
• Defects and Defects Per Million Opportunities (DPMO)
• Calculating Sigma Levels/Sigma Rating
• Lean Measures

Measure Phase Tollgate Review 

• The Analyse Phase Detail
• Sources of Variation and Root Cause Analysis
• Root Causes Analysis
• Determining Sources of Variation (SOV)
• Data Analysis vs Process Analysis
• The 5-Why’s Technique
• Dis aggregation/Stratification of Data
• Fish bone Diagram Revisited
• The Cause and Effect Matrix
• Process Complexity Analysis/Failure Mapping
• Process Deployment Chart

The Analyse Phase Detail 2

• Sources of Variation and Root Cause Analysis
• Root Causes Analysis
• Determining Sources of Variation (SOV)
• Structured Analytical Tools and Frameworks
• Data Analysis vs Process Analysis
• The 5-Why’s Technique
• Fish bone Diagram Revisited
• The Cause and Effect Matrix
• Dis aggregation/Stratification of Data
• Process Analysis
• Process Complexity Analysis/Failure Mapping
• Process Deployment Chart
• Verification Tools
• Failure Modes and Effects Analysis

The Analyse Phase Detail 3

• Problem Solving for Intangible and Conceptual Problems
• Affinity Diagram
• Relationship Diagram
• Systematic Diagram
• Allocations Matrix
• Lean Analysis Techniques
• Process Value Stream Analysis/Current State
• Toyota’s 4 Rules
• Flow Analysis – Time Traps and Constraints
• Waste Analysis
• Lean Lenses
• Analysis Phase Tollgate Review

The Improve Phase Detail 1

• Generating Potential Solutions
• Fish bone Diagram applied to improvement
• Systematic Diagram applied to improvement
• Process Improvement Checklist
• Technology Enablement
• Failure Modes and Effects Analysis

The Improve Phase Detail 2

• Lean approaches to Improve
• Creating Process Stability
• Toyota’s Four Rules
• 5-S
• Poka-Yoke and Mistake-Proofing
• Standardized Work
• Kaizen
• Solution Assessment and Selection
• Process Modelling
• Potential Solutions Matrix
• Decision Matrix
• Implementation Planning
• Simulation and Piloting
• Barriers and Aids Analysis
• Qualitative Risk Analysis
• Introduction to Design for Six Sigma
• Improve Phase Tollgate Review
• Control Phase Detail
• The Process Scorecard
• The Process Management and Control System