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Pivotal Resources - Continuous Improvement

 

Lean Six Sigma Green Belt Training Agenda

The following is a typical Lean Six Sigma Green Belt training agenda. Pivotal Resources can customize the course material to client training requirements, as well as certification objectives.

Pivotal’s Green Belt Training is an in-depth learning experience that covers the what, why and how of Lean Six Sigma Process Improvement. Participants learn a wide array of business skills and tools that drive results-oriented change, and apply them to real-life improvement projects. In addition to a solid foundation in the DMAIC process, the workshop demonstrates how to apply Lean and Six Sigma concepts to issues that arise every day.

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Introduction
  • Getting Started: Introductions
  • Key Outcomes
  • Agenda Review
  • Course Objectives
Lean Six Sigma Overview
  • What and Why Lean Six Sigma
    • What is Lean Six Sigma; a measure, a goal and a system
    • Key themes
    • Lean Six Sigma roadmap
  • Lean Six Sigma Strategies
    • Benefits of Lean Six Sigma
  • Lean Six Sigma Success Stories
  • Lean Six Sigma Success Factors
    • Proactive management
    • Customer focus
    • Process focus
    • Measures and data
    • Boundaryless collaboration
      ACTIVITY: Teams to discuss how they think Lean Six Sigma can help in their organizations (30 min)
  • Lean Six Sigma Organization and Roles
    • Lean Six Sigma structure
    • Roles and responsibilities
  • DMAIC Process Overview
    • DMAIC Action Model
    • Advantages of DMAIC process
Define
  • Identifying and Selecting Improvement Projects
    • Types of quality projects
    • Criteria for project selection
    • Prioritizing and selecting projects
  • Defining the Project & Preparing a DMAIC Project Charter
    • Business Case
    • Problem/Opportunity statement
    • Goal statement
      ACTIVITY: Critiquing problem and goal statements (15 min)
    • Constraints and assumptions
    • Scope
    • Players and roles
    • Preliminary plan
      ACTIVITY: Create rough draft charter and select team roles and responsibilities for your project (30 min)
  • Identifying the Customer and Process
    • Types of customers
    • Voice of the Customer data gathering
    • Understanding customer requirements
      ACTIVITY: Critiquing requirements (30 min)
    • Translating VOC into requirements
      ACTIVITY: Gathering VOC and stating requirements (20 min)
    • SIPOC model and process mapping
      ACTIVITY: Create a SIPOC (7 min)
    • Sub-process mapping
      ACTIVITY: Create a detailed process map for one sub-process within your project (35 min)
Measure
  • Principles of measurement
    • Why measure?
    • Measurement plan
  • Deciding What and Where to Measure
    • Identifying key output “Y” measures for the process
    • Measurement assessment
    • Types of measures
    • Stratification
      ACTIVITY: Develop key questions about your process and complete a measurement assessment (50 min)
  • Operational definitions and Data Sources
    • Creating operational definitions
    • Identifying data Sources
      ACTIVITY: Calculate standard deviation (10 min)
  • Sampling & Data Collection Forms
    • Sampling
    • Data collection forms
      ACTIVITY: Develop a sampling plan and data collection tools to be used for your project (60 min)
  • Testing, Refining and Implementing Measurement
  • Data Consistency and Stability
    ACTIVITY: Develop a measurement plan (35 min)
  • Process Performance and Capability Measures
    • Defect Measures
      • Yield, Rolled Throughput Yield, Defects per unit, Defects per million opportunities
        ACTIVITY: Calculate, RTY and DPMO (25 min)
    • Process capability
    • Process dashboards and balanced scorecards
Analyze
  • Process Analysis
    • Value/Non-value added analysis
    • Workflow principles and cycle time
      ACTIVITY: Complete a value and cycle time analysis (45 min)
  • Data Analysis
    ACTIVITY: Practice exercise related to variation (5 min)

    • Pareto charts
    • Variation factors
    • Histograms
    • Run charts
    • Box plots
      ACTIVITY: Create Pareto and Run Charts (35 min)
  • Considering Process Design/Redesign
    • Key differences
    • Benefits and challenges
    • Managing design/redesign
  • Develop Root Cause Hypothesis
    • Developing hypotheses
    • Cause and effect
    • Comparative analysis and logical cause testing
      ACTIVITY: Work on root cause analysis for your project, formulate hypothesis, construct cause and effect diagram (45 min)
  • Investigate and Verify Root Cause
    • Scatter diagrams
      ACTIVITY: Interpret scatter plots and determine correlation (10 min)
    • Correlation coefficients
    • Logical cause testing
    • Chi-square test
    • Cause verification
      ACTIVITY: Chi-square calculation (25 min)
    • Confidence testing

Introduction to Minitab [optional chapter]

Improve
  • Generating Solution Ideas
    • Creating innovative ideas
    • Planning for brainstorming sessions
    • Brainstorming and advanced idea generation techniques
      ACTIVITY: Practice using advanced idea generation techniques to develop a list of potential solutions (20 min)
  • Narrowing Ideas and Developing Proposed Solutions
    • Tools for solution filtering
    • “Should Be” process mapping
  • Selecting the Best Solution
    • Cost Benefit Analysis
    • Criteria matrix (review)
      ACTIVITY: Mini-Case Study using criteria matrix (30 min)
    • Planning and Testing the Improvement Solution
    • Planning and project management
    • Piloting
      ACTIVITY: Prepare a piloting strategy based on case study (30 min)
    • Unintended consequences
    • Risk management
    • FMEA (Failure Modes and Effects Analysis)
      ACTIVITY: Practice using FMEA on proposed solution (30 min)
    • Mistake proofing
  • Evaluating, Refining and Expanding Solutions
    • Implementation planning

Control
  • Control Plan
  • Planning Ongoing Measurement
    • Monitoring SIPOC
    • Dashboard review
    • Ongoing Measurement Tools
    • Control Charts
    • Use and interpretation
    • Construction methods
      ACTIVITY: Create a control based on predetermined data (15 min)
  • Developing Documentation
    ACTIVITY: Understanding the importance of documentation (25 min)

    • Documentation Hints
  • Preparing Revision and Response Plans
    ACTIVITY: Draft a sample control plan (7 min)
  • Expanding the Gains & Concluding the Project
    • Institutionalization
    • Translating opportunities
    • Storyboards
    • Continuous improvement

Review/Conclusion

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