Lean Six Sigma Green Belt Curriculum

Day 1: Introduction to Lean Six Sigma & Define Phase

Morning Session (4 hours)

Objective: Understand Lean Six Sigma principles and the role of Green Belts in process improvement projects.

• Introduction to Lean Six Sigma

  • Overview of Lean: Focus on waste reduction and process optimization.

  • Overview of Six Sigma: Focus on reducing variation and improving quality.

  • Synergy between Lean and Six Sigma: Why combining them leads to optimal outcomes.

• The DMAIC Methodology

  • Define, Measure, Analyse, Improve, Control.

  • Overview of the DMAIC framework and its purpose in process improvement.

Afternoon Session (4 hours)

Objective: Learn how to define project scope, goals, and customer needs during the Define phase.

• Define Phase:

  • Project Charter: Importance and how to write one.

  • Voice of the Customer (VOC): Collecting and analysing customer requirements.

  • SIPOC Diagram: Mapping the suppliers, inputs, process, outputs, and customers.

  • Problem Statement & Goal Statement: Clear articulation of the problem and desired outcomes.

Activity: Participants will work on creating a project charter and SIPOC diagram based on a sample process.

Day 2: Measure Phase

Morning Session (4 hours)

Objective: Learn how to measure current performance and understand the metrics to track progress.

• Measure Phase:

  • Data Collection Plan: Identifying what data to collect, how to collect it, and frequency.

  • Types of Data: Continuous vs. Discrete data, and which one is appropriate for the project.

  • Sampling Techniques: Understanding random sampling and sample size determination.

  • Measurement Systems Analysis (MSA): Verifying the accuracy and precision of measurement systems (Gage R&R).

Afternoon Session (4 hours)

Objective: Understand how to quantify process performance.

• Process Mapping & Flowcharts:

  • Flowcharting: Creating flowcharts to visualize the process.

  • Swimlane Diagrams: Mapping process flows with responsibilities.

• Basic Statistical Tools for Measurement:

  • Introduction to Descriptive Statistics (Mean, Median, Mode, Standard Deviation).

  • Using control charts (e.g., X-bar, R, and P-charts) to monitor process stability.

  • Pareto Analysis: 80/20 rule in identifying key process issues.

Activity: Participants will create a flowchart of a sample process and analyse data using control charts.

Day 3: Analyse Phase

Morning Session (4 hours)

Objective: Learn how to analyse data to identify root causes of problems and process inefficiencies.

• Analyse Phase:

  • Hypothesis Testing: Understanding different types of tests (t-test, chi-square, etc.) and when to use them.

  • Root Cause Analysis: Tools for identifying root causes (5 Whys, Fishbone Diagram).

  • Correlation and Regression: Using these techniques to analyse relationships between variables.

  • FMEA (Failure Modes and Effects Analysis): Identifying potential failure modes and their impact.

Afternoon Session (4 hours)

Objective: Apply analysis techniques to real-world process improvement.

• Tools for Process Improvement:

  • Scatter Diagrams: Plotting variables to detect correlations.

  • Box Plots: Analysing data spread and identifying outliers.

  • Brainstorming and Affinity Diagrams: Gathering and categorizing ideas for improvement.

Activity: Use Root Cause Analysis (5 Whys or Fishbone Diagram) to analyse a specific process issue in small groups.

Day 4: Improve and Control Phases

Morning Session (4 hours)

Objective: Learn how to implement improvements and ensure the gains are sustained over time.

• Improve Phase:

  • Solution Generation: Brainstorming potential solutions and selecting the best options.

  • Designing Experiments (DOE): Testing improvements systematically to determine effectiveness.

  • Risk Management: Mitigating risks in the improvement process.

• Control Phase:

  • Control Plans: Creating control plans to monitor improvements.

  • Standardization: Developing Standard Operating Procedures (SOPs) to sustain improvements.

  • Control Charts: Using control charts to monitor process stability over time.

Activity: Participants work on developing control plans and SOPs for their own process improvement projects.

Afternoon Session (4 hours)

Objective: Prepare for the 3 hour exam and understand the importance of maintaining improvements.

• Review of Key Concepts:

  • Quick review of DMAIC and key Lean Six Sigma tools.

  • Examples of successful Lean Six Sigma projects.

Activity: Group discussion on potential improvement projects at their workplaces. Facilitators will help identify the most suitable project based on their roles.

Day 5: Exam Preparation and Exam (3 Hours)

Morning Session (3 hours)

Objective: Ensure participants are ready for the exam.

• Review and Practice Test:

  • Review key tools and techniques learned over the past 4 days.

  • Practice exam questions covering all aspects of the curriculum (Define, Measure, Analyse, Improve, Control).

• Final Q&A:

  • Answer any remaining questions or doubts about the material.

Afternoon Session (3 hours)

Objective: Administer the Lean Six Sigma Green Belt Exam.

• 3-Hour Exam:

  • The exam consists of multiple-choice questions, and short-answer questions that test participants’ understanding of Lean Six Sigma concepts and their ability to apply them.