Lean Six Sigma Green Belt Course Outlines

Module 1: Understanding Six Sigma

• Six Sigma as a Symbol, Value, Measure, Metric, Benchmark, Method, Tool, Goal, Philosophy
• History of Six Sigma (Motorola, GE, Honeywell, Lockheed Martin, etc.)
• DMAIC Roadmap Introduction
• Define Phase Deliverables
• Problem-Solving Strategy: Y = f(X) (Cause & Effect Thinking)
• Six Sigma Strategy & Breakthrough Approach (VOC, VOB, VOE)
• Six Sigma Roles & Responsibilities (Executive, Champion, MBB, BB, GB, YB)
• Certification Path and Organizational Behaviors

Module 2: Six Sigma Fundamentals

• What is a Process? (Definition, Examples, Process Focus)
• Process Mapping (Symbols, High-Level Maps, Cross-Functional Maps, Swim Lanes)
• Voice of the Customer (VOC) & Critical-to-Quality (CTQ) Characteristics
• Types of Customers (Internal vs. External, Value Chain)
• Cost of Poor Quality (COPQ) – Elements, Tangible vs. Intangible Costs
• COPQ and Lean (Waste Categories, Hard vs. Soft Savings)
• Basic Six Sigma Metrics
  • Defects per Unit (DPU)
  • First Time Yield (FTY)
  • Rolled Throughput Yield (RTY)
  • Defects per Million Opportunities (DPMO)
  • Cycle Time Metrics

Module 3: Measure Phase 

(Based on Six Sigma DMAIC flow – this follows Define)

• Establishing Measurement Systems
• Data Collection Planning
• Process Capability Analysis
• Measurement System Analysis (MSA)
• Baseline Process Performance

Module 4: Analyze Phase

• Root Cause Analysis
• Hypothesis Testing
• Regression & Correlation
• Cause & Effect Analysis

Module 5: Improve Phase

• Solution Design & Piloting
• Lean Tools for Improvement
• Mistake Proofing (Poka-Yoke)
• Implementation Planning

Module 6: Control Phase

• Control Plans & Documentation
• Standard Operating Procedures (SOPs)
• Statistical Process Control (SPC)
• Sustaining Improvements

Lean Six Sigma Black Belt Course Outlines

Module 1: Define Phase

• Understanding Six Sigma (symbol, value, measure, metric, benchmark, method, tool, goal, philosophy)
• History of Six Sigma (Motorola, GE, evolution of DMAIC)
• Six Sigma Strategy & Breakthrough Thinking (Y = f(X), Vital Few vs. Trivial Many)
• Voice of the Customer (VOC), Voice of the Business (VOB), Voice of the Employee (VOE)
• Roles & Responsibilities (Executive Leadership, Champions, MBB, BB, GB, YB)
• Project Selection & Charter Development
• Stakeholder Analysis & Team Dynamics
• Process Mapping (high-level, cross-functional, swim lanes, symbols)
• Critical-to-Quality (CTQ) Development
• Cost of Poor Quality (COPQ) – Hard vs. Soft, Tangible vs. Intangible
• Basic Six Sigma Metrics: DPU, DPMO, RTY, FTY, Cycle Time

Module 2: Measure Phase

• Process Analysis & Data Collection Planning
• Types of Data: Continuous vs. Discrete
• Sampling Methods & Bias Reduction
• Measurement System Analysis (MSA, Gage R&R)
• Statistical Foundations: Normality, Distribution Properties
• Process Capability: Cp, Cpk, Pp, Ppk, Sigma Level
• Rolled Throughput Yield (RTY) & Yield Estimation Models
• Value Stream Mapping & Cycle Time Analysis
• X-Y Matrix (Input-Output Analysis)
• Measurement Deliverables & Data Integrity

Module 3: Analyze Phase

• Hypothesis Testing Foundations (p-values, Type I & II errors)
• Comparative Tests: t-test, ANOVA, Chi-Square
• Correlation & Regression Analysis (simple, multiple, logistic)
• Advanced Statistical Tools: DOE Screening, Factorial Designs
• Root Cause Analysis Tools: Fishbone, 5 Whys, Fault Tree
• Pareto Principle & Prioritization of Causes
• Failure Modes and Effects Analysis (FMEA)
• Advanced Process Analysis (Non-normal data, Nonparametric tests)
• Identifying Vital Few X’s (Critical Inputs)

Module 4: Improve Phase

• Creative Problem Solving & Solution Generation
• Lean Tools: 5S, Kaizen, Kanban, Standard Work, Waste Elimination
• Mistake-Proofing (Poka-Yoke)
• Process Redesign & Benchmarking
• Design of Experiments (DOE) – Full, Fractional, Response Surface Methods
• Optimization Techniques & Simulation Models
• Piloting Solutions – Risk & Impact Assessment
• Change Management & Overcoming Resistance
• Financial Evaluation of Improvements (ROI, Payback, Hard vs. Soft Savings)

Module 5: Control Phase

• Control Plans & Documentation
• Standard Operating Procedures (SOPs)
• Statistical Process Control (SPC): Control Charts for Variable & Attribute Data
• Control Limits vs. Specification Limits
• Error-Proofing in Sustained Systems
• Visual Management Tools & Dashboards
• Knowledge Transfer & Handover to Process Owners
• Institutionalizing Continuous Improvement Culture
• Linking Improvements to Strategic KPIs
• Audits, Governance & Certification Requirements

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