Lean Six Sigma Green Belt Curriculum

The programme

Programme overview

A Lean Six Sigma Green Belt curriculum designed for managers over 5 days provides a comprehensive understanding of Lean Six Sigma principles, tools, and methodologies. This course enables supervisors to lead or participate in improvement projects and utilize data to identify, analyse, and solve process-related issues. The training concludes with a 3-hour exam to assess understanding. Candidates must have a matric with Maths.

Who should attend

Who is this programme for?

Contact Ratomac to confirm suitability for your role and prior experience.

Learning outcomes

What you will learn

By the end of the Lean Six Sigma Green Belt Curriculum course, participants will be able to:

• Lead or participate in process improvement projects.
• Apply Lean Six Sigma tools to measure, analyse, improve, and control processes.
• Use data to identify issues and determine root causes.
• Create and implement improvement plans.
• Sustain improvements through standardization and control.
• Receive International Accreditation from the Council for Six Sigma Certification (CSSC), enhancing their credibility in Lean Six Sigma.

Explore the programme

Detailed programme outline

Day 1: Introduction to Lean Six Sigma & Define Phase

Morning Session (4 hours)

Objective: Understand Lean Six Sigma principles and the role of Green Belts in process improvement projects.

• Introduction to Lean Six SigmaOverview of Lean: Focus on waste reduction and process optimization.Overview of Six Sigma: Focus on reducing variation and improving quality.Synergy between Lean and Six Sigma: Why combining them leads to optimal outcomes.
• The DMAIC MethodologyDefine, Measure, Analyse, Improve, Control.Overview of the DMAIC framework and its purpose in process improvement.

Afternoon Session (4 hours)

Objective: Learn how to define project scope, goals, and customer needs during the Define phase.

• Define Phase:Project Charter: Importance and how to write one.Voice of the Customer (VOC): Collecting and analysing customer requirements.SIPOC Diagram: Mapping the suppliers, inputs, process, outputs, and customers.Problem Statement & Goal Statement: Clear articulation of the problem and desired outcomes.

Activity: Participants will work on creating a project charter and SIPOC diagram based on a sample process.

Day 2: Measure Phase

Objective: Learn how to measure current performance and understand the metrics to track progress.

• Measure Phase:Data Collection Plan: Identifying what data to collect, how to collect it, and frequency.Types of Data: Continuous vs. Discrete data, and which one is appropriate for the project.Sampling Techniques: Understanding random sampling and sample size determination.Measurement Systems Analysis (MSA): Verifying the accuracy and precision of measurement systems (Gage R&R).

Objective: Understand how to quantify process performance.

• Process Mapping & Flowcharts:Flowcharting: Creating flowcharts to visualize the process.Swimlane Diagrams: Mapping process flows with responsibilities.
• Basic Statistical Tools for Measurement:Introduction to Descriptive Statistics (Mean, Median, Mode, Standard Deviation).Using control charts (e.g., X-bar, R, and P-charts) to monitor process stability.Pareto Analysis: 80/20 rule in identifying key process issues.

Activity: Participants will create a flowchart of a sample process and analyse data using control charts.

Day 3: Analyse Phase

Objective: Learn how to analyse data to identify root causes of problems and process inefficiencies.

• Analyse Phase:Hypothesis Testing: Understanding different types of tests (t-test, chi-square, etc.) and when to use them.Root Cause Analysis: Tools for identifying root causes (5 Whys, Fishbone Diagram).Correlation and Regression: Using these techniques to analyse relationships between variables.FMEA (Failure Modes and Effects Analysis): Identifying potential failure modes and their impact.

Objective: Apply analysis techniques to real-world process improvement.

• Tools for Process Improvement:Scatter Diagrams: Plotting variables to detect correlations.Box Plots: Analysing data spread and identifying outliers.Brainstorming and Affinity Diagrams: Gathering and categorizing ideas for improvement.

Activity: Use Root Cause Analysis (5 Whys or Fishbone Diagram) to analyse a specific process issue in small groups.

Day 4: Improve and Control Phases

Objective: Learn how to implement improvements and ensure the gains are sustained over time.

• Improve Phase:Solution Generation: Brainstorming potential solutions and selecting the best options.Designing Experiments (DOE): Testing improvements systematically to determine effectiveness.Risk Management: Mitigating risks in the improvement process.
• Control Phase:Control Plans: Creating control plans to monitor improvements.Standardization: Developing Standard Operating Procedures (SOPs) to sustain improvements.Control Charts: Using control charts to monitor process stability over time.

Activity: Participants work on developing control plans and SOPs for their own process improvement projects.

Objective: Prepare for the 3 hour exam and understand the importance of maintaining improvements.

• Review of Key Concepts:Quick review of DMAIC and key Lean Six Sigma tools.Examples of successful Lean Six Sigma projects.

Activity: Group discussion on potential improvement projects at their workplaces. Facilitators will help identify the most suitable project based on their roles.

Day 5: Exam Preparation and Exam (3 Hours)

Morning Session (3 hours)

Objective: Ensure participants are ready for the exam.

• Review and Practice Test:Review key tools and techniques learned over the past 4 days.Practice exam questions covering all aspects of the curriculum (Define, Measure, Analyse, Improve, Control).
• Final Q&A:Answer any remaining questions or doubts about the material.

Afternoon Session (3 hours)

Objective: Administer the Lean Six Sigma Green Belt Exam.

• 3-Hour Exam:The exam consists of multiple-choice questions, and short-answer questions that test participants’ understanding of Lean Six Sigma concepts and their ability to apply them.

Learning approach

How you will learn

Our diverse instructional approaches ensure effective learning:

– Lectures & Presentations: Engage with expert-driven, stimulating content.– Course Material: Access well-crafted supporting resources.– Group Work: Collaborate on discussions and case studies for practical insights.– Workshops & Role-Play: Participate in immersive, scenario-based activities.– Practical Application: Focus on applying theoretical knowledge in real situations.– Post-Training Support: Receive extensive support after training for skill implementation.

Discuss your requirements

Dates, duration & arrangements

Contact Ratomac to confirm dates, duration, delivery format, entry requirements and any applicable assessment or certification before booking.