Training Agenda: Six Sigma Green Belt Certification
Duration: 64 Hours (8 Days)
Target Audience: Professionals involved in process improvement, quality management, and those seeking to lead Six Sigma projects or support Black Belt projects.
Objective: To equip participants with the knowledge and skills to lead Six Sigma projects using DMAIC methodology, statistical tools, and Lean principles. By the end of the course, participants will be able to apply Green Belt-level Six Sigma tools and methods to solve complex process problems.
Day 1: Introduction and Define Phase (8 hours)
Registration and Welcome
- Introduction to Six Sigma and the role of the Green Belt
- Course objectives and structure
- Participant introductions and goals
Overview of Six Sigma
- What is Six Sigma? Concepts and goals
- History and evolution of Six Sigma
- The Six Sigma hierarchy: Yellow Belt, Green Belt, Black Belt, Master Black Belt
- Key Six Sigma terms: Defects, DPMO, Sigma levels, CTQ, and COPQ (Cost of Poor Quality)
- The role of Lean principles in Six Sigma
Break
Introduction to DMAIC
- Overview of the DMAIC (Define, Measure, Analyze, Improve, Control) methodology
- How DMAIC helps solve complex problems
- The structure and deliverables of each phase of DMAIC
Lunch Break
Define Phase: Identifying Projects
- Selecting Six Sigma projects: Criteria and examples
- Project Charters: Defining scope, goals, and deliverables
- Identifying Critical to Quality (CTQ) elements and Voice of the Customer (VOC)
- SIPOC (Suppliers, Inputs, Process, Outputs, Customers) Diagram
- Practical exercise: Creating a SIPOC diagram and project charter
Break
Define Phase: Project Planning and Management
- Stakeholder analysis and team roles in Six Sigma projects
- Tools for effective project planning and management
- Gantt charts, RACI matrix, and project risk management
- Practical exercise: Developing a project management plan
Day 2: Measure Phase – Part 1 (8 hours)
Measure Phase: Introduction to Data and Measurement Systems
- Purpose of the Measure phase: Establishing baselines
- Types of data: Continuous vs. Discrete
- Data collection planning: Sampling strategies and methods
- Introduction to Measurement System Analysis (MSA)
- Gage R&R (Repeatability and Reproducibility) overview
Break
Measurement System Analysis (MSA)
- Conducting MSA: Gage R&R studies
- Attribute Agreement Analysis (AAA)
- Interpreting MSA results
- Practical exercise: Performing a Gage R&R study
Lunch Break
Process Mapping and Data Collection
- Introduction to Process Flow Diagrams and Value Stream Mapping (VSM)
- Using flowcharts to document process steps and identify bottlenecks
- Practical exercise: Creating a Process Flow Diagram for a real-world scenario
Break
Baseline Performance and Process Capability
- Calculating process capability (Cp, Cpk, Pp, Ppk)
- Interpreting capability indices for process improvement
- Practical exercise: Capability analysis with real-world data
Day 3: Measure Phase – Part 2 (8 hours)
Data Analysis Techniques
- Basic statistics review: Mean, Median, Mode, Range, and Standard Deviation
- Introduction to statistical tools in Six Sigma
- Descriptive statistics and graphical analysis
Break
Control Charts for Data Monitoring
- Introduction to control charts: X-bar, R, P, NP, C, and U charts
- How to select and use control charts for different data types
- Practical exercise: Developing and interpreting control charts
Lunch Break
Introduction to Minitab or Excel for Six Sigma
- Overview of Six Sigma software tools (e.g., Minitab)
- Basic functions in Minitab for data analysis and control charts
- Practical exercise: Using Minitab/Excel for statistical analysis
Break
Measure Phase Review and Case Study
- Review of Measure phase key concepts and tools
- Case study: Applying Measure phase tools to a real-world problem
- Group discussion and Q&A
Day 4: Analyze Phase – Part 1 (8 hours)
Analyze Phase: Identifying Root Causes
- Purpose of the Analyze phase: Finding the root cause of process problems
- Introduction to root cause analysis (RCA)
- Cause-and-effect (Fishbone) diagram
- Practical exercise: Conducting a root cause analysis with a Fishbone diagram
Break
Hypothesis Testing Basics
- Introduction to hypothesis testing in Six Sigma
- Understanding p-values, null and alternative hypotheses
- Introduction to types of tests: T-tests, ANOVA, Chi-square tests
- Practical exercise: Setting up and conducting a hypothesis test
Lunch Break
Correlation and Regression Analysis
- Exploring relationships between variables: Correlation vs. causation
- Simple linear regression analysis
- Practical exercise: Performing a correlation and regression analysis
Break
Failure Mode and Effects Analysis (FMEA)
- What is FMEA and its role in the Analyze phase?
- Conducting a process FMEA
- Practical exercise: Completing an FMEA for a process
Day 5: Analyze Phase – Part 2 (8 hours)
Advanced Data Analysis Tools
- Introduction to more advanced statistical tools: ANOVA and Chi-square
- Practical exercise: Using ANOVA and Chi-square for analyzing process data
Break
Review of Analyze Phase
- Consolidation of key Analyze phase tools and methods
- Case study: Applying Analyze tools to a real-world scenario
Lunch Break
Group Exercise: Comprehensive Analyze Phase Application
- Group-based exercise applying all tools from the Analyze phase to a case study
- Presentation of results and group feedback
Day 6: Improve Phase (8 hours)
Improve Phase: Generating Solutions
- Techniques for brainstorming and solution generation
- Prioritizing improvements with Impact/Effort Matrix
- Introduction to Poka-Yoke (Mistake Proofing)
- Practical exercise: Generating improvement solutions for a process
Break
10:45 AM – 12:30 PM | Lean Tools in the Improve Phase
- Lean improvement techniques: 5S, Kaizen, SMED (Single-Minute Exchange of Die)
- Implementing Lean in Six Sigma projects
- Practical exercise: Applying Lean tools to process improvements
Lunch Break
Piloting and Validating Solutions
- Testing solutions with pilot projects
- Design of Experiments (DOE) basics
- Practical exercise: Setting up and analyzing a pilot project
Process Simulation and Optimization
- Using simulation tools to optimize processes
- Practical exercise: Process simulation and solution optimization
Day 7: Control Phase (8 hours)
Control Phase: Sustaining Improvements
- Introduction to control plans
- Developing Standard Operating Procedures (SOPs) for process control
- Practical exercise: Creating a control plan for an improvement
Break
Statistical Process Control (SPC)
- Using SPC charts to monitor ongoing process performance
- X-bar and R charts, P charts for attribute data
- Practical exercise: Implementing SPC in a process
Lunch Break
Control Charts and Process Audits
- Introduction to process audits for sustained control
- Implementing visual management and control mechanisms
- Practical exercise: Conducting a mock process audit
Control Phase Review
- Comprehensive review of control tools and techniques
- Case study: Applying Control phase tools to a real-world project
Day 8: Case Studies, Certification Exam, and Wrap-Up (8 hours)
Final Case Study Review
- Group presentation of a comprehensive DMAIC case study
- Discussion and feedback from peers and instructors
Break
Six Sigma Green Belt Exam
- Green Belt certification exam (optional based on certification body)
- Exam review and feedback
Lunch Break
Wrap-Up and Q&A
- Key takeaways and final thoughts
- Participant feedback and certification distribution
- Q&A and final discussion