LEAN SIX SIGMA TRAINING

Lean / Six Sigma White Belt Session Outline (Can be half-day or 1-day session)

-What is Lean?  What is Six Sigma?
-How Lean and Six sigma can improve any process 
-Value-Added (VA) and Non Value-Added (NVA) activities 
-Recognizing NVA/waste through ‘8 wastes analysis’ and waste walks 
-Tools to see and understand the process and identify waste (7 Basic tools)
-Value stream mapping and process mapping
-Just in Time, Balance, Flow and Pull 
-The benefits of an improved ‘Leaned’ process 
-5S and the Visual Workplace 
-Kaizen/Rapid Improvement events 
-Error-proofing 
-Work cell design
-Sustaining improvement through Standard Work and effective Control Plans 
-Lean/ Six Sigma structure and roles 
-Your expectation and likely involvement with Lean / Six Sigma in the future

Lean Six Sigma Yellow Belt (4 days) 

-Fundamental concepts and principles of Lean and Six Sigma
-Lean Six Sigma DMAIC and DMADV methodology
-Lean Six Sigma Roles and Structure
-Lean Six Sigma Metrics and Statistics
-Explain the fundamental concepts and principles of Lean Enterprise
-Introduction to lean concepts, tools and techniques
-Value-added and non value-added activities
-How Lean concentrates on waste identification and reduction
-Understanding the Voice of the Customer (VOC) and Voice of the Process (VOP)
-Rationale and benefits of implementing a Lean Six Sigma approach
-The eight sources of waste (Muda) plus Mura (Unevenness) and Muri (Overburden)
-Cost of Quality/Cost of Poor Quality
-The use of A3 problem-solving methodology
-Effective problem statements using the 5W2H approach
-Construct SIPOC, Process Flow and Spaghetti Maps
-Effective Operational Definitions
-Prepare an effective data collection plan
-Rank and prioritize using Pareto Charts
-Construct current and future state Value Stream maps and deeper-dive process maps
-Value Added Assessment and ‘the Hidden Factory’
-Cause & Effect diagrams and drill down to root cause using ‘5 Whys’ approach
-Assess process capability (Cp/Cpk/PPk) and sigma level using DPMO and Rolled Throughput Yield
-Descriptive Statistics (central tendency & dispersion)
-Use basic graphical analysis tools including Box Plots & Histograms
-Understand how to Plan and participate in Kaizen improvement events
-Batch Reduction, Kanban, Leveling and Improving Flow 
-Workplace organization including 5S, visual workplace & standardized work
-The use of process control charts and control plans to sustain improvements

Lean Six Sigma Green Belt (Additional 4 days for LSS Yellow Belts with the following topics – Total 8 days:)

-Change Management, Leadership and Culture (the ‘People Side’ of improvement)
-Project Identification, prioritization, and completion – Kanban Boards, Impact/Effort Analysis
-Project Charters and A3 Methodology 
-Identifying Waste and improvement opportunities (‘8 Wastes’ and Gemba/Waste Walks) 
-Implementing and tracking performance improvements
-Data Collection Planning
-Sampling and Sample Sizes
-Measurement Systems Analysis (MSA)
-Statistical Process Control
-Capability Analysis
-Hypothesis Testing
-Scatter Plots
-Regression
-Introduction to Design of Experiments (DOE)
-Failure Modes & Effects Analysis
-Error-Proofing
-Lean Six Sigma Improvement Techniques
-Quick Changeover Techniques
-Total Productive Maintenance and Overall Equipment Effectiveness (OEE)
-Work cell Design 
-Planning and Leading Kaizen Events 
-5S and Visual Workplace
-Quick/Rapid Changeover (SMED)
-Ongoing Control Methods for Sustainment (Control charts, Reports, Audits, etc.)
-Implementing Daily Management, Standard Work, Layered Audits and Leader Standard Work

Lean Six Sigma Black Belt (Additional 8 days for Lean Six Sigma Green Belts – Total of 16 days)

-Hoshin Planning
-Deployment Planning and Implementation:     
-Daily Management, Standard Work, Leader Standard Work, Metrics and Visual Management
-Leading and Managing Projects
-Advanced Lean Topics: Theory of Constraints, Error-Proofing, Mapping Approaches, Time Studies, Work Cells, 
-Quality Function Deployment
-Design for Lean Six Sigma
-Statistical Software Training and Analysis
-Design of Experiments
-Distribution Identification and Analysis
-Design of Experiments (DOE)
-Advanced Statistical Analysis – Logistic and Multiple Regression, Non-normal analysis, Multi-Vari, MSA
-Train-the-Trainer, Coaching and Training, Planning and Leading 5S and Kaizen events
-Leadership and Champion roles and responsibilities
-Facilitating and Leading Teams