Lean Six Sigma Green Belt (Case Study Based)

Course details

Lean Six Sigma has become the fastest spreading and most successful approach to Continuous Improvement across all industries regardless of size, position in the supply chain or service provided. An essential element of Lean Six Sigma roll-out is Green Belt training. This case study based Lean Six Sigma Green Belt course works through the DMAIC approach to process improvement providing delegates with the critical tools involved in the Define, Measure, Analyse, Improve and Control phases. Delegates will learn how to use these tools in characterising processes, analysing process data, stabilizing and controlling processes. This Lean Six Sigma Green Belt workshop will expose delegates to the powerful tools and methodology necessary to successfully lead and contribute to DMAIC improvement projects within the organisation.

Course Schedule

• Training will take place on 16-17 September, 14-16 October 2014 in Dublin.

Course Content

Step 1. Define

Aim

To successfully launch a Lean Six Sigma Green Belt project by refining a project charter, leading a project team, garnering support for the project from process stakeholders and ensuring a common understanding of the process across all project participants and stakeholders.

Learning Outcomes

On successful completion of this subject the learner will be able to:

• Explain the DMAIC methodology that the project will follow
• Define a narrowly scoped problem statement using data to quantify the problem and its impact(s) on the organisation
• Undertake high level process mapping to assess the requirements of internal and external process customers to ensure these are understood by all team members and align with project goals
• Form, and function within, a project team comprising of peers from different functions with whom the learner has an established working relationship.
• Review and refine the project charter to minimize risks to successful project completion
• Create a basic communications plan to ensure stakeholders are kept informed of the projects progress at regular intervals
• Create a basic project plan to ensure the project is completed on time

Step 2: Measure

Aim

To develop a factual and accurate picture of the current state of process performance, identifying areas of weakness within the process for further investigation and achieving ‘quick win’ improvements where possible.

Learning Outcomes

On successful completion of this subject the learner will be able to:

• Construct a suitable map of a process with the input of process experts (limited to Deployment, IPO, Flow Maps and Spaghetti maps)
• Identify waste and potential weaknesses in processes via analysis of process maps, input from process experts, observation or other suitable means.
• Prepare a basic data collection plan to gather data from the process to address areas of uncertainty among process experts.
• Evaluate process stability and capability of a process, where required
• Assess adequacy of process measurement systems and/or create operational definitions for new measures

Step 3: Analyse

Aim

To understand the drivers of poor performance in a process and select focus areas for improvement actions.

Learning Outcomes

On successful completion of this subject the learner will be able to:

• Identify causal relationships in a process using basic graphical analysis and team brainstorming techniques (eg. fishbone diagrams)
• Complete 5 why root cause analysis to investigate systemic drivers of variation and/or waste in a process
• Prioritise possible sources of waste/variation to a shortlist for further investigation
• Conduct basic graphical analysis of data to answer questions regarding shortlisted factors

Step 4: Improve

Aim

To develop and implement optimum, sustainable solutions with minimum resistance from stakeholders in the organisation

Learning Outcomes

On successful completion of this subject the learner will be able to:

• Use creative thinking techniques to identify many potential solutions
• Select appropriate solutions from a list of possible solutions
• Demonstrate the effectiveness of chosen solutions using pilot studies, test data or post implementation data
• Identify sources of resistance to proposed solutions and develop plans to overcome this resistance
• Plan the implementation of a solution to a well defined problem considering effective change control, training of personnel and verification of effectiveness of the solution.

Step 5: Control

Aim

To verify solutions have been implemented effectively and ongoing controls are institutionalized in the organisation

Learning Outcomes

On successful completion of this subject the delegate will be able to:

• Standardise and simplify work practices to reduce potential for variation in process outputs
• Select appropriate control techniques for ongoing process control including statistical process controls as appropriate
• Create a process control plan to identify responsibility for maintaining process performance at the new, desired level
• Communicate recommendations for further improvement to project stakeholders and customers, as appropriate

Learning Outcomes

The aim of the programme is to produce graduates who possess the pre-requisite knowledge of theory and practice of Lean Six Sigma to enable them to participate in process improvement efforts in their organisations. This includes successfully leading a Green Belt Team and contributing in a practical and value-added manner to a Black Belt Team Project.

On successful completion of this programme the graduate will:

• Have a good understanding of a variety of graphical and team based problem solving tools and the manner in which these are combined in the process of solving well defined and narrowly scoped business problems
• Have a good understanding of basic statistical concepts while recognizing limits of current knowledge
• Be able to apply well established technical and creative tools to solve well defined and narrowly scoped process problems
• Understand how to formulate a project plan to undertake well defined and narrowly scoped process engineering projects
• Be able to employ an investigative and data driven approach to establish the source of well defined process engineering problems
• Be able to identify, and plan for effective implementation of, solutions to a variety of well defined process engineering problems
• Be able to work effectively as a member of a cross functional problem solving team, often taking responsibility for the work of team members
• Have a good appreciation of the importance of effective communication in managing organisational change

Course Entry Requirements

Each delegate must complete an Application Form for entry to the programme.

• Leaving Certificate with minimum of C on lower level mathematics or
• A person who has demonstrated the achievement of this level by approved prior experiential learning (APEL)
• Fundamental competence in basic Microsoft Office suite of software
• A laptop with the most recent version of SigmaXL software. (On Public courses, this software will be supplied to delegates by SQT and is included in the course fee. On In-House courses, SQT can supply the software licences if required or should your organisation currently use an alternative software package (such as SPCXL or Minitab) this can be used.
• Competence in English language
• Skills that are considered necessary for successful participation in the programme include:
• willingness to learn (reading, research)
• good communication skills
• ability to self direct