Six Sigma is one of the best professional certifications that enhance the skills of an individual in problem-solving, leadership and the ability to use data and analytics to drive process improvements. Certified Six Sigma Professionals will have exponential growth in career, preference over other candidates in interviews and a minimum of 30% higher salary for the same position. The main advantage of Six Sigma over other certifications is that it can be applied to any industry like Manufacturing, Healthcare, Hospitality, Construction, Oil & Gas or Education.
What is Six Sigma?
Six Sigma is a powerful methodology that can be used to improve business processes. It is a structured approach to problem-solving that can be applied to any process – manufacturing, sales, marketing, IT, BPO, accounting, purchasing, you name it. All processes have variation. Variation is the cause of all errors – it leads to defects and customer dissatisfaction. Six Sigma methodology can be used to reduce variation from any source and thus reduce costs, improve quality, and hence customer satisfaction.
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Lean Six Sigma Green Course Objectives
Upon completing the Lean Six Sigma Green Belt, participants will be able to:
- Gain an in-depth understanding of quality improvement methodology.
- Adopt a process-centric approach to streamline operations.
- Analyze the flaws in existing processes and rectify the same.
- Develop problem-solving skills to address the issues identified in the initial phase.
- Reduce wastage of resources in the process.
- Take data-driven decisions to improve the processes.
- Eliminate errors and reduce variations in the processes to increase the success of the project.
- Manage stakeholders effectively to meet organizational goals.
- Improve leadership skills in driving efficient projects, managing processes and people.
- Lead and supervise a team of professionals working on process improvement.
- Develop a continuous improvement culture and sustainable quality improvement.
The Lean Six Sigma Green Belt has been designed to build your knowledge and capability to improve the performance of processes and subsequently the performance of the business of which you are a part. The focus of the course is process centric.
Module I – Introduction to Lean and Six Sigma
- Introduction to Quality
- Introduction to Lean
- Principles of Lean
- The 3 Ms
- Introduction to Six Sigma
- Evolution of Lean Six Sigma as an integrated approach
- How does Lean Six Sigma align to organisation goals?
- Overview of 5 Phased DMAIC Methodology
- Roles and Responsibilities in a Lean Six Sigma Project
Module II – Define Phase
- Identifying a potential Lean Six Sigma Project
- Validating if a project is suitable for the LSS Methodology
- Components of a Process
- Develop COPIS/ SIPOC
- Process to Gather VoC
- Kano Model for VoC
- Translate VoC to CTQs
- Develop Project Charter
- Analyse Project Stakeholders
Module III – Measure Phase
- Sources of Information – Process Door and Data Door
- Importance of Understanding As-is Process
- Value Stream Mapping
- Takt Time
- Types of Data
- 5 Step Data Gathering Approach
- What to measure: Input, Process, Output Measures
- How much data to collect: Sample size calculation
- Data Measurement Plan
- Validate Measurements
- Collect Data
- Calculate Baseline Performance: DPMO, Sigma Score
Module IV – Analyse Phase
- Establish Cause and Effect Relationship
- Introduction to Process Analysis & Data Analysis
- Key Focus Areas in Process Analysis
- Techniques for Process Analysis
- ESCAP Analysis
- The Eight Wastes
- Techniques for Data Analysis
- Stratification
- Pareto
- Identify Potential Root Cause(s)
- Fishbone/ Cause & Effect/ Ishikawa Diagram
- Control Impact Matrix
- 5 Why
- Validate Potential Root Causes
Module V – Improve Phase
- Develop Potential Solutions
- Preparation for Brainstorming
- Brainstorming Techniques
- Prioritise Solutions
- Prioritisation Techniques
- Design Go to Process
- Kaizen
- Kanban
- 5S
- Poka Yoke
- Cellular Design
- Validate Potential solutions with Pilot
- Correct/Re-Evaluate Potential Solution
- Update Policies, Process Flows and Procedures
- Train staff
- Implement validated solutions.
Module VI – Control Phase
- Develop Hand-over Plan
- Process Management Plan
- Complete Hand-over to Process Owner
- Obtain sign-off on Project Benefits
- Close Project
- Celebrate
The Lean Six Sigma Black Belt credential is the highest and an advanced level certification that signifies a mastery of Lean and Six Sigma principles, empowering individuals with advanced skills in data analysis, problem-solving, and project management.
Module I – Introduction to Statistics and Estimation
- Introduction to Statistics
- Measures of Central Tendency & Dispersion
- Types of Variation
- Normal Distribution
- Characteristics of Normal Distribution
- Control Limits and Specification Limits
- Normal Distribution versus Standard Normal Distribution
- Areas and Probabilities in a Normal Curve
- Probabilities of Defects – Intro to Z – Value
- Empirical Cumulative Distribution Function
- Estimation – Graphical Summary
- Confidence Interval and Confidence Level
- Calculate Baseline Performance: FPY, TPY, RTPY, Process Capability
Module II – Data Visualisation Tools
- Normal Probability Plot
- Visualising Data with Single Variable
- Histogram
- Box Plot
- Pie Chart
- Bar Chart
- Visualising Data with two Variables
- Scatterplot
- Box Plot with Groups
- Transposed Box Plot
- Stacked Bar Graph
Module III – Hypothesis Testing
- Root Cause Validation using Statistical Thinking
- Introduction to Hypothesis Testing
- Understanding Null/ Alternate Hypothesis & p-Value
- Steps to perform Hypothesis Testing
- Types of Hypothesis Tests & Process
- 1 Sample z- Test
- 1 Sample t-Test
- ANNOVA
- 2 – Sample T Test
- Kruskal Wallis Test
- Linear Regression
- Logistic Regression
- Chi-Square Analysis
- Overview of Design of Experiments
Module IV – Control Charts
- Introduction to Statistical Process Control
- Common Cause versus Special Cause
- Components of a Control Chart
- Rational Sub-Grouping
- Tests in Control Charts
- Types of Control Charts
- I-MR Chart
- X-Bar R Chart
- X-Bar S Chart
- P Chart
- NP Chart
- U Chart
- C Chart