Lean Six Sigma Yellow Belt + Green Belt: Leading Continuous Improvement

Module 1: Introducing continuous improvement

• The definition, challenges and benefits of continuous improvement.
• Problem solving: general methodology and the 5 Whys.
• Continuous improvement challenges: competitiveness, sustainability and resistance to change.
• Selecting an improvement strategy: criteria and examples.
• Main continuous improvement methodologies: comparison and complementary roles of Lean, Six Sigma, TQM and others.

Module 2: Exploring Lean Six Sigma methods

• The origins of Lean in the Toyota Production System and Six Sigma at Motorola.
• The normal distribution.
• The relationship between Six Sigma and DPMO (Defects per Million Opportunities).
• The difference between 3.8 Sigma and 6 Sigma.
• Sigma levels and the cost of poor quality.
• Lean Six Sigma pillars: understanding and meeting customer needs, optimising processes to eliminate waste, engaging and training employees, developing strong supplier relationships, and measuring and continually improving performance.
• Lean's organisational and cultural dimensions: critical customer needs, process definition, performance and objective management, organisational structure and the Lean team approach.
• The 8 sources of waste (MUDA): exercises identifying waste in a process.
• Kaizen events: principles, delivery and benefits.

Module 3: Exploring DMAIC in depth

• Define: critical customer needs, problem statements, SMART objectives, project benefit assessment, project team formation, SIPOC development, stage planning, project charter and tollgate review.
• Measure: key performance indicators (KPIs), data collection tools, basic statistical tools (histograms, Pareto charts and scatter plots), and process capability calculations (Cp, Cpk).
• Analyse: cause analysis tools (Ishikawa diagrams, 5 Whys and root cause analysis), advanced statistical tools (hypothesis testing, ANOVA and linear regression), and decision trees.
• Improve: brainstorming and creativity techniques, Design of Experiments (DOE), and solution selection and implementation.
• Control: Statistical Process Control (SPC) plans, performance monitoring indicators and process standardisation.

Module 4: Using specific tools and techniques

• Agile project management and its compatibility with Lean Six Sigma.
• Project monitoring tools: Kanban and dashboards.
• Effective communication in a Lean Six Sigma project.
• Leadership and team facilitation.
• Change management.
• Advanced statistical tools: logistic regression and survival analysis.
• Problem-solving techniques: 8D and Failure Mode, Effects and Criticality Analysis (FMECA).
• Project management tools: PERT and CPM.
• Soft skills: negotiation, effective presentations and conflict management.

Module 5: Deploying and managing a Lean Six Sigma project

• The 6 key elements of Lean Six Sigma implementation.
• Preparing deployment.
• Building a Lean Six Sigma project team: roles and responsibilities.
• Establishing governance.
• Integrating Lean Six Sigma into organisational strategy.
• The Hoshin Kanri X-matrix.
• Developing skills.
• Lean Six Sigma success factors.
• Selecting a real project and applying DMAIC.
• Presenting results and recommendations.

Module 6: Preparing for the Lean Six Sigma Green Belt exam

• Different Lean Six Sigma certifications and their criteria.
• Review of the key points covered throughout the course.
• Detailed exam overview: structure, format and topics.
• Exam preparation guidance: approach, time management and other techniques.