Lean Six Sigma Agenda

Black Belt

This four week curriculum follows the DMAIC methodology (Define, Measure, Analyze, Improve, and Control).  Both Lean and Six Sigma tools are fully integrated in each phase.  The modules are packed with manufacturing, operations, and transactional/services examples. The course includes simulations and hands-on case studies for tool application, and concludes with a cumulative capstone exercise.

Introduction to Lean Six Sigma

Define Phase

  • Introduction to Define and Gate Reviews
  • The Project Charter
  • Project and Change Management
  • Multigenerational Project Planning
  • Gathering Voice of the Customer

Measure Phase

  • Introduction to Measure
  • Document and Analyze the Process
  • Cause and Effect Matrix
  • Minitab Overview
  • Introduction to Basic Statistics
  • Data Collection
  • Understanding Variation and Control Charts
  • Measurement System Analysis (MSA)
  • Process Capability
  • Key Lean Concepts
  • Transactional Lead Time Simulation

Analyze Phase

  • Introduction to Analyze
  • Root Cause ID and Validation
  • FMEA
  • Confidence Intervals
  • Hypothesis Testing
  • Means, Medians and Variance Tests (Including ANOVA and Non-Parametrics)
  • Quick Improvement Methods
    • Quick Wins and Kaizen
    • 5S
    • Process Flow Improvement
    • Changeover Reduction
  • Simple & Multiple Linear Regression
  • Proportion and Chi Square Tests
  • Multi-Vari Analysis

Improve Phase

  • Introduction to Improve
  • Core Simulation Round 1
  • Solution Development
  • Quick Improvement – CONWIP/Work Control Systems
  • Core Simulation Round 2
  • Quick Improvement – ABC Part Stratification
  • Quick Improvement – TPM
  • Replenishment Pull Systems
  • Core Simulation Round 3
  • Pre-DOE Exercise
  • Introduction to Design of Experiments (DOE)
  • Full Factorial DOE
  • Fractional Factorial DOE
  • DOE Planning
  • DOE Catapult Simulation
  • Implementation

Control Phase

  • Introduction to Control
  • Mistake Proofing
  • Process Control Methods
  • Visual Control Methods
  • Extending the Improvements
  • Project Close-Out
  • Cumulative Case Study
  • Review and Final Test

Green Belt

This two week curriculum follows the DMAIC methodology (Define, Measure, Analyze, Improve, and Control).  Both Lean and Six Sigma tools are fully integrated in each phase.  The modules are packed with both manufacturing and transactional/services examples.  Our unique format makes it easy to learn and easy to teach.

Introduction to Lean Six Sigma

Define Phase

  • Introduction to Define
  • The Project Charter
  • Project and Change Management
  • Key Lean Concepts
  • Transactional Lead Time Simulation
  • Gathering Voice of the Customer

Measure Phase

  • Introduction to Measure
  • Document and Analyze the Process (Value Stream Mapping)
  • Cause and Effect Matrix
  • Introduction to Basic Statistics
  • Determine What to Measure and Data Collection
  • Understanding Variation and Control Charting
  • Measurement System Analysis (MSA)
  • Process Capability

Analyze Phase

  • Introduction to Analyze
  • Root Cause ID and Validation
  • FMEA
  • Introduction to Hypothesis Testing
  • Means and Variance Tests
  • Simple Linear Regression

Improve Phase

  • Introduction to Improve
  • Solution Development
  • Quick Wins and Kaizen
  • 5S
  • Process Flow Improvement
  • Intro to Design of Experiments (Optional)
  • Full-Factorial Designs (Optional)
  • DOE Simulation (Optional)
  • Implementation

Control Phase

  • Introduction to Control
  • Mistake Proofing
  • Process Control Methods

Yellow Belt

Learn the basics of Lean Six Sigma with a fun, interactive three-round simulation. The simulation will take you through the DMAIC process and introduce you to some basic Lean Six Sigma tools, as you apply them to a simulated transactional process. The simulation can be run in groups of six to twenty.

Our Yellow Belt training is a 1-day workshop that we have developed based on our 20+ years of experience introducing Lean Six Sigma methodologies, tools, and techniques to new practitioners. The workshop is highly interactive, based on a three-round simulation where students will apply the tools to improve a process as a team.

Topics covered include:

  • The history of Lean and Six Sigma
  • The DMAIC methodology
  • The Project Charter
  • Voice of the Customer
  • SIPOC
  • Histograms
  • Pareto charts
  • Value Stream Mapping
  • Takt time
  • Value-added analysis
  • TIMWOODS
  • Process loading charts
  • Process control
  • Poke-yoke

At the end of the workshop, participants leave with an understanding of the Lean Six Sigma approach, along with some tools that they can immediately apply in their job.