Certified Lean Six Sigma® Green Belt

Module 1: introduction to continuous improvement

• What is continuous improvement? Definition, challenges and benefits.
• Problem solving: general methodology and the 5 Whys method.
• Challenges of continuous improvement: competitiveness, sustainability and resistance to change.
• Choosing an improvement strategy: criteria and examples.
• Main continuous improvement methodologies: comparison and complementarity (Lean, Six Sigma, TQM, etc.).

Module 2: introduction to Lean Management

• The origins of Lean: the Toyota production system.
• Real case studies: successes and failures in Lean implementation.
• The organisational and cultural dimensions of Lean:
  • Identify critical customer needs.
  • Define a process.
  • Manage performance and define objectives.
  • Organise the company structure.
  • Adopt a Lean team approach.
• The main Lean principles: value, waste, continuous flow and perfection.
• The 8 sources of waste (MUDA): exercises identifying waste in a process.
• Kaizen events: principles, process and benefits.

Module 3: introduction to the Lean Six Sigma method

• What is the Lean Six Sigma method?
• The origins of Lean (Toyota production system) and Six Sigma (Motorola).
• The pillars of Lean Six Sigma:
  • understand and satisfy customer needs;
  • optimise processes to eliminate waste;
  • engage and train employees;
  • develop strong relationships with suppliers;
  • measure and continually improve performance.
• The relationship between Lean and Six Sigma.

Module 4: in-depth understanding of the DMAIC methodology

• Define phase
  • Defining critical customer needs.
  • Describing a problem.
  • Defining the objective (SMART).
  • Assessing project benefits.
  • Assembling the project team.
  • Building the SIPOC.
  • Planning project stages.
  • The project charter.
  • The phase review or Tollgate.
• Measure phase
  • Key performance indicators (KPIs): definition, selection and monitoring.
  • Data collection tools: questionnaires, observations and direct measurements.
  • Basic statistical tools: histograms, Pareto charts and scatter plots.
  • Calculating process capability (Cp, Cpk).
• Analyse phase
  • Cause analysis tools: Ishikawa diagrams, 5 Whys and root cause analysis.
  • Advanced statistical tools: hypothesis tests, ANOVA and linear regression.
  • Building decision trees.
• Improve phase
  • Brainstorming and creativity techniques.
  • Design of experiments (DOE): principles and applications.
  • Selecting and implementing solutions.
• Control phase
  • Statistical process control (SPC) plans.
  • Performance monitoring indicators.
  • Process standardisation.

Module 5: 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 method and FMEA analysis).
• Project management tools (PERT and CPM).
• Soft skills (negotiation, effective presentations and conflict management).

Module 6: managing a Lean Six Sigma project

• Assembling the project team.
• Choosing a real project.
• Applying the DMAIC methodology to a real project.
• Presenting results and recommendations.

Module 7: preparing for the Six Sigma Green Belt exam

• Introduction to the different Lean Six Sigma certifications and criteria.
• Reviewing key points covered throughout the course.
• Detailed introduction to the exam (structure, format and topics covered).
• Tips and advice for passing the exam (methodology, time management, etc.).