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

Transformation and Control Charts
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