Lean Six Sigma Green Belt Training and Certification Abacus Team Inc. Objective The purpose of this training is to provide a methodology and tools to enable the participants to use Lean Six Sigma tools, to better execute projects workshops, from initiation to closure Understand the Lean Six Sigma methodology and concepts Apply it to Operational Products and Services value streams (processes) Identify sources of variation, wastes and constraints Find and implement solutions to remove these wastes and constraints, reduce or eliminate variation, cutting down time, cost, effort, defects. Understand how to establish a plan to bring a business or service on the road of profitability increase using these concepts Method Theory will be given regularly throughout the training The participants will progress through the exercises, from the problem definition to the solutions. A Lean Six Sigma Green Belt Certificate will be given upon successful completion of the exam, completion of the training, and submission of a project plan. The certificate will be signed by, Certified Master Black Belt 1
Agenda Day 1 1. Overview of Lean Six Sigma a. Context of continuous improvement b. Applications i. Process improvements ii. Product improvements c. Overview of the methodology and phases i. The 6 phases - RDMAIC ii. The metrics 1. Variation and waste 2. Sigma level, DPMO, yields, rolled throughput yield cost of poor quality 3. Time management: lead time, cycle time iii. Exercises on the metrics a. Overview of the Lean concepts iv. Value, 7 wastes, takt time v. Value stream vi. Flow and 1 piece flow vii. Pull viii. Perfection 2. Recognize and Define phase (phase 1): defining the problem and the project a. Selecting the right projects to improve i. Strategic plans as a source ii. SWOT analysis iii. Benchmarking iv. Project trees v. Benefit vs effort matrix vi. Selection matrix vii. The SMART concept viii. Multi generation project plans b. Defining the project (project definition, SIPOC) i. Mission statement ii. SIPOC iii. Overview of project management 10 key process areas iv. Force field analysis c. Setting objectives d. Defining the project team e. Team exercise on project identification and prioritization using a custom case study 2
3. Measure introduction and Statistical notions review a. Average, median, mode, range,standard deviation b. Histograms c. Behaviour of the Gaussian (normal) distribution d. Exercises on these notions Day 2 4. Recap questions 5. Measure phase (phase 2): measuring the actual performance a. Defining metrics related to the objectives i. Overview of the metrics flow down ii. Overview of the Quality Function Brainstorming iii. Brainstorming rules iv. Cause and effect diagrams, 5W v. 5W2H b. Mapping the process or the product c. Analysis of the mapping i. Risks, failure modes (FMEA) ii. Value added, non-value added principles iii. Team exercise on a problematical process d. Value stream mapping i. Value stream mapping vs Process Mapping ii. Value stream mapping steps and rules iii. Analysis: wastes, clouds, bottleneck, takt time iv. Discuss the impact of setup time on business and operational flows v. Team exercise on a value stream map analysis e. Data collection i. Planning the data collection ii. Sampling strategies iii. Biases iv. Overview of measurement system analysis 1. Variable gauge R&R 2. Attribute gauge R&R 3
Day 3 6. Recap questions 7. Measure phase (phase 2): measuring the actual performance (continued) a. Process capability i. Recap on normality ii. Metrics: Cp, Cpk, DPMO iii. Interpretation iv. Ppk and Pp v. Link with Z tables and Z values vi. Exercises : calculation and interpretation b. Standard Work and Standard Work Combination Sheets (as assessment tools) 8. Analyze phase (phase 3): identifying the vital factors a. Reviewing the process map conclusions b. Importance of graphing the data c. Scatter plots and regression i. Correlation and regression ii. Linear regression iii. Multiple regression overview 1. Linear multiple regression 2. ANOVA table simple interpretation iv. Overview of other hypothesis testing tools d. Graphical tools and interpretation i. Run chart, bar graphs ii. Pareto Chart, Pie chart iii. Scatter plots recap iv. Scatter plot e. Understanding the variation: i. Control charts: natural limits and specification limits ii. Variation: random or assignable f. Selection of the factors to improve g. Team exercise on graphics generation and identification of the critical x s 9. Improve phase (phase 4): selection the right solution a. Selecting the right solution b. Creativity tools i. Functional analysis related brainstorming ii. Brainteasers c. Scenario evaluations and selection i. Recap of matrices ii. Pugh matrix and Pugh principle 4
d. Overview of mistake proofing e. Pilot and implementation planning f. Team exercise on defining a pilot and change management plan Day 4 10. Recap question 11. Control phase (phase 5): maintaining the improvements a. Setting a control plan b. Overview of 5S and visual management c. Post mortem and audits d. Evaluation the gains e. Control charts and statistical process control (SPC) i. Xbar- R, I-MR charts ii. p, np, u, c charts iii. Overview if other chart types f. SPC Normalization for small lots Z-MR charts g. Team exercise on establishing a control plan h. Exercises on control chart selection 12. Recap exercise Going through the entire methodology using a custom case study 5