Lean Six Sigma Green Belt

EngineRoom

Course Map

Total Estimated Hours: 80

SESSION 1: Introduction to Lean Six Sigma 4 HOURS

A MoreSteam Welcome
Introduction to Lean Six Sigma
The Cost of Poor Quality
Input Determines Output
The 5 Lean Principles
The 8 Forms of Waste
History of Lean Six Sigma
The 99.9% Problem

DMAIC Improvement Process
Thought Process Mapping Toolset
Organizing for Success
Roles and Responsibilities
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
Gantt Chart Toolset
Leadership Thinking
Robot Leadership
Fueling The Improvement Engine
Leading Teams
Developing an Effective Team

Improving Team Development
4 Conversations Toolset
Change Management I: Leading Change
Change Management II: Change is a Process
Change Management III: Delivering Results
Leader Standard Work Toolset
RACI Matrix
Leadership Reflection
Session Wrap-Up and Skill Check

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

Introduction to Voice of the Customer
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
Calculating 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
Introduction to Process Mapping
The Source of Value
Gemba Walks
Types of Process Maps
SIPOC Map Toolset
Process Flow Charts

Value-Added Flow Charts
Spaghetti Diagrams
Takt Time
Value Stream Mapping Toolset
Define Phase 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
Solving Problems with Statistics
Basic Statistical Terms
Descriptive and Inferential Statistics
Measurement and Data Types
Discrete vs. Continuous Measurements
Selecting the Best Measurement
Graphical Summaries
Graphical Summaries II
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
Introduction to Measurement Systems Analysis (MSA)
Measurement System Requirements
MSA for Continuous Data: Gauge R&R
MSA for Attribute Data
Calibration of Measurement Systems

Data Collection
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 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 Simulation: Chart Noir
Process Capability Toolset
Containment
Measure Phase 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
The Path to Root Cause
Writing Effective Problem Statements
Cause and Effect Diagram Toolset
5-Why, 1-How Analysis
Root Cause Tree Analysis Toolset

Scatter Plot Toolset
Simple Regression Analysis
Multiple Regression Analysis 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
Multiple Means Test (ANOVA)
Hypothesis Test Simulation: HyCourt TV
Analyze Phase Progress Review
Session Wrap-Up and Skill Check
St. Sigma Case Study Analyze

SESSION 10: Improve 12.05 HOURS

Introduction to the Improve Phase
Design for Six Sigma
Benchmarking
Brainstorming
Structured Brainstorming
Multi-Voting
FMEA Toolset
Error-proofing
Prioritizing and Selecting a Solution
The A3 One-Page Report
Continuous Flow Toolset
Line Balancing (Heijunka)

Quick Changeover Toolset
Cellular Processing Toolset
Introduction to Pull Systems
Types of Pull Systems
Core Process Pull Systems (WIP Cap) Toolset
Kaizen Toolset
Corrective Action Matrix
Piloting a Solution
System Dynamics Toolset
Improve Phase 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
Process Control Plan
Prioritizing Changes with FMEA
Visual Management
5-S Approach
Introduction to Total Productive Maintenance (TPM)
TPM Objectives and Benefits
TPM Metrics

Best Practices
Standard Work
Project Close-Out
Control Phase Progress Review
Session Wrap-Up and Skill Check
St. Sigma Case Study Control
Course Completion and Feedback
The Lean Six Sigma Journey