Lean Six Sigma Green Belt - EngineRoom

Course Map

Total Estimated Hours:  80

SESSION 1: Introduction to Lean Six Sigma 4 HOURS

  • Introduction
  • Introduction to Lean Six Sigma
  • The Cost of Poor Quality
  • Input Determines Output
  • The 5 Lean Principles
  • The 8 Forms of Waste
  • Success Stories
  • The 99.9% Problem
  • DMAIC - The Improvement Process
  • Thought Process Mapping - Toolset
  • Organizing for Success
  • Working Relationships
  • Introduction to EngineRoom®
  • Learning and Problem Solving with AI
  • Session Wrap-Up and Skill Check

SESSION 2: Define I - Starting a Project and Leading Teams 6.95 HOURS

  • Introduction to the Define Phase
  • Project Selection Toolset
  • Project Charter Toolset
  • Project Planning & Tracking Toolset
  • Leadership Thinking
  • Robot Leadership
  • Fueling The Improvement Engine
  • Leading Teams
  • Developing an Effective Team
  • Improving Team Development
  • 4 Conversations Toolset
  • The Change Challenge
  • Leading Change
  • Success Factors For Effective Change Management
  • Leader Standard Work Toolset
  • Stakeholder Analysis - RACI Matrix
  • Leadership Reflection
  • Session Wrap-Up and Skill Check

SESSION 3: Define II - Voice of the Customer 5.95 HOURS

  • Voice of the Customer Introduction
  • Understanding Customer Requirements
  • Where to Go For Customer Requirements
  • Conducting Surveys
  • Survey Considerations
  • Surveys - Sampling Frame
  • Structuring Survey Questions
  • The Degree of Uncertainty in Sampling
  • Guideline for Margin of Error
  • Affinity Diagram Toolset
  • CTQC Tree Diagram Toolset
  • Operational Definition Toolset
  • Voice Of The Customer As Specifications
  • Session Wrap-Up and Skill Check

SESSION 4: Define III - Mapping the Process 5.7 HOURS

  • Drawing a Process Picture
  • Process Thinking
  • The Source of Value
  • The Source of Value: Gemba
  • Process Mapping - Overview
  • Process Mapping (SIPOC) Toolset
  • Flow Charts
  • Value-Added Flow Charts
  • Spaghetti Charts
  • Takt Time
  • Value Stream Mapping Toolset
  • Define Tollgate - Progress Review
  • Session Wrap-Up and Skill Check
  • St. Sigma Case Study Define

SESSION 5: Measure I - Measurements and Basic Statistics 7.75 HOURS

  • Introduction to the Measure Phase
  • Business Problem Solving
  • Basic Statistical Terms
  • Descriptive and Inferential Statistics
  • Measurements
  • Discrete vs. Continuous Measurements
  • Measurement Subjects
  • Graphical Summaries
  • Graphical Summaries Pt. 2
  • Pareto Chart Toolset
  • Histogram Toolset
  • Understanding Variation
  • Measuring Central Tendency
  • Quantifying Process Variability
  • Box Plots Toolset
  • The Normal Distribution
  • Distribution Identification
  • Data Cleansing
  • Session Wrap-Up and Skill Check

SESSION 6: Measure II - Measurement System Analysis 8.55 HOURS

  • Measurement System Analysis - Introduction
  • Measurement as a Process
  • Cause & Effect Matrix Toolset
  • The Analysis of Measurement Systems
  • The Requirements of Measurement Systems
  • Variable MSA - Gauge R & R
  • Attribute Measurement System Analysis
  • Calibration of Measurement Systems
  • Collecting Data
  • Developing a Sampling Plan
  • Baseline Performance
  • Derivative Performance Metrics - Throughput Yield
  • Derivative Performance Metrics - Rolled Throughput Yield
  • Calculating DPMO and Sigma Level
  • Session Wrap-Up and Skill Check

SESSION 7: Measure III - Charting Process Behavior 10.8 HOURS

  • Introduction - Charting Process Behavior
  • Trend Chart (Run Chart) Toolset
  • SPC - Introduction and Background
  • SPC - Introduction to Control Charts
  • SPC - Control Chart Limits
  • SPC - More On Control Limits
  • Implementing SPC
  • SPC Chart Selection
  • Rational Subgrouping Toolset
  • X and Moving Range Charts - Toolset
  • Data Transformation
  • Attribute Control Chart Toolset
  • X-bar and R Chart Toolset
  • SPC Using Stage Variables
  • Control Chart Case Study - Chart Noir
  • Process Capability Toolset
  • Containment
  • Measure Tollgate - Progress Review
  • Session Wrap-Up and Skill Check
  • St Sigma Case Study Measure

SESSION 8: Analyze I - Identifying Potential Root Causes 7.65 HOURS

  • Introduction to the Analyze Phase
  • Finding The Root Cause
  • Problem Definition
  • Cause & Effect Diagram Toolset
  • 5-Why, 1-How
  • Root Cause Tree Analysis Toolset
  • Scatter Plot Toolset
  • Correlation and Regression Analysis
  • Multiple Regression Toolset
  • Factors In Determining Sample Size
  • Session Wrap-Up and Skill Check

SESSION 9: Analyze II - Hypothesis Testing 11.2 HOURS

  • Statistical Testing
  • Introduction to Hypothesis Testing
  • The Process On Trial
  • The Hypothesis - Accept or Reject?
  • Types of Error
  • Hypothesis Testing
  • Confidence Intervals
  • Treatment Comparisons - Control Charts
  • Comparing Two Proportions Toolset
  • Comparing Two Means - t-Test Toolset
  • Comparing Multiple Means - ANOVA Toolset
  • Hypothesis Testing Learning Lab
  • Analyze Tollgate - Progress Review
  • Session Wrap-Up and Skill Check
  • St Sigma Case Study Analyze

SESSION 10: Improve 12.05 HOURS

  • Introduction to the Improve Phase
  • Excellence by Design
  • Benchmarking
  • Brainstorming
  • Structured Brainstorming
  • Narrowing Down The List of Ideas
  • FMEA Toolset
  • Error-proofing
  • Prioritizing and Selecting a Solution
  • The A3 One-Page Report
  • Continuous Flow Toolset
  • Leveling Production (Heijunka)
  • Quick Changeover Toolset
  • Cellular Processing Toolset
  • Pull System Overview
  • Pull Scheduling
  • Core Process Pull Toolset
  • Kaizen Toolset
  • Corrective Action Matrix
  • Piloting a Solution
  • System Dynamics Toolset
  • Improve Tollgate - Progress Review
  • Session Wrap-Up and Skill Check
  • St Sigma Case Study Improve

SESSION 11: Control 5.95 HOURS

  • Introduction to the Control Phase
  • Control Charts Revisited
  • The Process Control Plan
  • More On FMEA
  • Visual Management
  • 5-S Approach
  • Total Productive Maintenance
  • TPM Objectives & Benefits
  • TPM Metrics
  • Best Practices and Lessons Learned
  • Standard Work - Documenting Process Changes
  • Project Close-Out
  • Control Tollgate - Progress Review
  • Session Wrap-Up and Skill Check
  • St Sigma Case Study Control
  • Course Completion and Feedback
  • The Lean Six Sigma Journey