Lean Six Sigma Greenbelt Course 9303; 5 days, Instructor-led

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1 Lean Six Sigma Greenbelt Course 9303; 5 days, Instructor-led Course Description This course covers basic DMAIC (Define, Measure, Analyze, Improve and Control) Six Sigma principles and tools, as well as Lean methodology. Students who successfully complete this course will have the confidence and skills to execute Six Sigma projects and apply Lean methodology to improve their businesses and reduce costs. Classes are taught by GE Certified Master Blacks with a proven track record for delivering training that ties theory with practical application. Please Note: This class cannot be taken via our virtual instructor-led (Direct2You) solution. Who Should Attend Any person in business can benefit from continuous improvement, training and application. Some of the potential benefits it could bring to you or your company. IT: Completed projects faster with fewer errors Finance: Reduce the days sales are outstanding, or the time it takes to close the books Manufacturing: Reduce scrap costs, increase capacity and reduce inventory HR: Reduce turnover and hiring costs Sales: Increase revenue and reduce the time it takes to return quotes Upon Completion: Goals Define Phase Be able to identify customer Determine what customer wants/needs Translate VOC into a CTQ Verify that the projects supports the business goals Create a high level process map Identify and address potential barriers Sign off by Key Stakeholders Create project charter Measure Phase Identify sources of variation Prioritize possible sources of variation Validate a measurement system

2 Collect data you need Assess current process performance Refine improvement goals Analyze Phase Identify the vital X s that you are able to control Improve Phase Identify critical X settings Learn the piloted solution that will achieve the project goal To be able to process a map Control Phase Be able to fully implement a new process Demonstrate improvement over time Update project database Identify translation database Course Outline 1. Class Introduction a. Agenda b. Course Objectives c. Expectations of Students & Instructor d. Certification Requirements e. Schedule f. Dishwasher Example g. Intro to Helicopter Exercise 2. Understanding Six Sigma a. Definitions b. History of Six Sigma c. Strategy d. Problem Solving e. Six Sigma Roles and Responsibilities 3. Six Sigma Fundamentals a. Process Mapping b. VOC - Voice of the Customer c. COPQ - Cost of Poor Quality d. The Basic Six Sigma Metrics - (Cycle Time, DPU, FTY, RTY)

3 4. Selecting/Defining Projects a. Selecting Projects i. Pareto Analysis b. Refining & Defining i. Business Case ii. Project Charter c. Financial Evaluation 5. Change Acceleration a. Change Acceleration Tools b. GRPI c. ARMI d. Stakeholder Analysis e. In Scope / Out of Scope f. Social Styles 6. Define Wrap Up a. Define Checklist 7. Welcome to Measure 8. Process Discovery a. Cause and Effect Diagram (Fishbone) b. X-Y Matrix c. Detailed Process Mapping d. FMEA 9. Six Sigma Statistics a. Notation Cheat Sheet b. Descriptive Statistics c. Normal Distribution d. Assessing Normality e. Special Cause / Common Cause f. Graphing Techniques i. Histogram ii. Box Plot iii. Time Series Plot 10. Measurement System Analysis (MSA)- Gage R&R a. Basics of MSA b. Continuous Data MSA c. Attribute Data MSA

4 11. Process Capability a. Data Collection Plan b. Process Capability i. Z-score c. Attribute Capability 12. Measure Wrap Up a. Measure Checklist 13. Introduction to Analyze Phase 14. "X" Sifting a. Multi-Vari Graphing b. Classes of Distribution 15. Inferential Statistics a. 5-Step Approach to Hypothesis Testing 16. Introduction to Hypothesis Testing a. Nature of Sampling b. Practical vs. Statistical Results c. Hypothesis Testing Steps d. Alpha Risk (Type 1 Error) "Producer's Risk" e. Beta Risk (Type 2 Error) "Consumer's Risk" f. Hypothesis Testing Common Pitfalls g. Hypothesis Testing Flow Chart #1 - Starting Point h. Hypothesis Testing Flow Chart #5 - Specialty Tests i. Hypothesis Testing Flow Chart #2 - Continuous-Normal Data j. Hypothesis Testing Flow Chart#3: Continuous-Non-Normal Data k. Hypothesis Testing Flow Chart #4: Attribute Data l. Hypothesis Tests Overview 17. Tests for Variance: Continuous Data (Normal Data) a. 1 Sample Variance Test (Graphical Summary) b. 2-Sample Variance Test (F-Test) c. > 2-Sample Variance Test (Bartlett's Test) - Bonus Problem 18. Tests for Comparing two Means: Continuous Data (Normal) a. 1-Sample Mean Test - (t-test) b. 2-Sample Mean Test - (t-test) [Variance Equal] c. 2-Sample Mean Test - (t-test) [Variance NOT Equal] d. > 2-Sample Mean Test - (One-Way ANOVA)

5 e. ANOVA Assumptions - Bonus Material f. ANOVA Residual Tests- Bonus Material 19. Hypothesis Testing Continuous Non-Normal Data a. Non-parametric Tests b. Non-parametric Flow Chart c. 1-Sample Variance d. 2 or more sample variance test (Levene's Test) e. Nonparametric Tests - Comparing Medians f. 1-Sample (Median) sign or 1-Sample (Median) Wilcoxon g. 2-Sample (Median)Mann-Whitney h. 2 or more samples Median - Mood's Median Test 20. Discrete Data Proportions a. Attribute Data Flow Chart b. Compare Proportion to a target c. Compare 2 Proportions d. Compare 2 or more Proportions - Contingency Table - Chi Square 21. Wrap Up Analyze 22. Introduction to Improve Phase 23. Process Modeling: Regression a. Correlation b. Introduction to Regression c. Simple Linear Regression 24. Design of Experiments (DOE) a. DOE Definition b. Graphical DOE c. Interaction d. Full Factorial Design 25. Fractional Factorial Design 26. Pilot Solution 27. Improve Phase Wrap Up a. Improve Checklist 28. Introduction to Control Phase

6 29. Defect Controls a. Defect Prevention b. Poka Yoke 30. Statistical Process Control a. Methodology b. SPC Selection c. Attribute SPC Selection d. Variable SPC Selection 31. Six Sigma Control Plans a. Control Plan b. Training Plan c. Documentation d. Monitoring Plan e. Response Plan 32. Control Phase Wrap Up a. Control Checklist 33. Understanding Lean a. Agenda b. Objectives c. Lean Pitfalls d. Toyota's Results e. History f. 3 Types of Work/Waste g. 7 Forms of Waste 34. Lean Techniques a. 5S b. Andon c. Takt Time d. Kaizen e. Kan Ban f. Poka Yoke g. Standard Work h. Single Piece Flow i. Visual Management j. Value Stream Map

7 35. Lean Philosophy a. Value b. Axioms c. Relationships d. People e. 8th Type of Waste 36. Executing a Sustainable Lean Transformation a. Objectives b. Change as a Process vs. an Event 37. Framework a. Understand b. Stabilize c. Continuously Improve

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