Lean Six Sigma – Green Belt Training Program (DMAIC)


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Overview

This 5-day workshop rigorously follows the DMAIC approach that provides participants with a globally-recognized methodology for rapidly and dramatically improving the output of their business processes. Participants will learn how improve their processes to maximize throughput, reduce costs and cycle time and improve overall quality. The course will also teach participants how to incorporate Lean principles into their improvement activities. These methodologies and tools, used world-wide, provides a reliable approach for rapidly achieving world class business performance improvement.

Approach

Held in a workshop format, this 5-day course is designed to teach participants how to effectively implement the DMAIC methodology of six sigma, while incorporating the tools of Lean. Graduates will be able to assist Lean Six Sigma (LSS) Black Belts in their improvement projects, and will also be able to lead their own LSS improvement projects.

Green Belt practitioners play a vital role in the company’s LSS effort, because they are the people who lead and execute the principles and practices of LSS on a daily basis. A Green Belt will learn how to focus on and use many of the proven LSS problem-solving and statistical tools to contribute to the success of the organization.

The focus of this workshop is to enable participants to implement LSS projects and achieve measurable improvements in the output of processes. SatiStar’s experts will support this training with on-site consultants to ensure that the use of the tools is applied effectively.

Participants will learn through lecture, class discussions, class exercises, case studies, on-site data homework consisting of process data collection and analysis, team breakouts and the implementation of a real-life LSS project using the DMAIC approach.

This course includes a written final examination that, together with the completion of the Green Belt project, leads to Green Belt Certification.

What You Will Learn

Participants will learn to:

  • Define:
    • Lean Six Sigma Overview
    • The DMAIC Process
    • Definitions
    • Lean tools
    • Project guidelines & selection
    • Project charters
    • SIPOC
    • Project planning
    • Project team members, roles, responsibilities
    • Project sponsorship
    • Project implementation approaches
    • Project timelines
    • The social aspects of six sigma
    • Providing appropriate leadership
    • Getting buy-in at all levels
    • Enlisting team sponsors, leaders, team members and customers
    • Presentation skills
    • Team-based skills and techniques
    • The Kaizen-Blitz approach
    • Group dynamics and control
    • Conflict management and resolution
  • Measure:
    • Process output measures
    • Internal process measures
    • Measurement System Analysis
    • Sampling
    • Rational Subgroups
    • Process Mapping
    • Value stream analysis
    • Cost of Quality
    • Basic Statistical Concepts
    • Process characterization
    • Process capability
  • Analyze:
    • Process analysis
    • Identifying enablers and inhibitors of process performance
    • Failure Mode and Effects Analysis
    • Cause & Effect Analysis
    • ANOM
    • ANOVA
  • Improve:
    • Removing NVA activities
    • Maximizing VA activities
    • Process improvement
    • 5S
    • Layout
    • Cellular / Flow
    • Pull / Kanban / Scheduling systems
    • TPM
    • POUS
    • Quality at Source
    • Quick Changeovers
    • Batch reduction
    • Visual factory / office
    • Standardization
    • Analysis of Variance
    • Analysis of Means
    • Regression Analysis
    • Mistake Proofing
    • Design of Experiments
    • Obstacles to six sigma and how to overcome them
    • Managing the transition
    • Critical success factors
  • Control:
    • Statistical Process Control
    • Control charts for Attributes data
    • Control charts for Variables data
    • How long to control?

Training Outcomes

Each student will be required to complete SatiStar’s statistical knowledge assessment prior to registration. Those accepted must bring at least 3 management approved green belt projects to the course.

Participants in this training are required to successfully complete a lean six sigma project prior to being certified.

Click here to download a PDF synopsis of this course!

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WHAT PEOPLE ARE SAYING

SatiStar's Experience Makes The Difference!

  • . . . worked extremely well with the departmental and site managers . . . goal oriented and met the objectives set within the quoted budget and ensured the results were attained for the Company.

  • The guys from SatiStar did more in one week than we were able to do in 6 months.

  • Achieving ISO registration was far less onerous than we thought, our employees really rallied to the cause. The registration effort really brought us closer together as a team, and SatiStar really came through for us when we needed them.

  • We started this process a year ago with Mickey helping us create a spaghetti map of our processes on the whiteboard, and then his team guided us through their streamlining methodology and got us to where we are today. Our processes now look nothing like the spaghetti map – and we’re much more efficient today

  • This projected cycle time reduction of over 80% annual cost savings amounting to over 3% of sales, one-time savings of roughly $10 million, and working capital reduction of roughly $30 million really have us excited!

  • An outstanding success with Motorola’s vendor audit! What made this an exceptional achievement is that it typically takes 4 to 5 attempts to pass this audit. SatiStar’s expertise made it easy to avoid all the extra attempts.