Lean Six Sigma. Green Belt.

Lean and Six Sigma are globally recognized methodologies for business process improvement. While Six Sigma focuses on reducing variation within processes, Lean emphasizes maximizing customer value across the entire value stream. Applying these methodologies in supply chain and manufacturing environments requires a practical, results-driven approach.

This course is designed for professionals who want to apply Lean Six Sigma directly to real-world operations. Delivered through a combination of in-person workshops, on-site coaching, and hands-on project work, participants will apply tools and concepts to real business problems on the shopfloor, achieving measurable improvements in their own work environments.

Course Structure

• Workshop sessions covering each phase of the DMAIC methodology

• Bi-weekly coaching on site or virtually to support project progress and tool application

• Weekly assignments based on actual operational data and process observations

• One-on-one project support to guide practical application on the shopfloor

Project Component

Each participant completes an improvement project within their workplace. The project follows the DMAIC framework and addresses a defined operational issue, from identifying the root cause to implementing and sustaining improvements. Projects are expected to deliver measurable business results.

Certification

Certification is awarded upon:

• Active participation in all course sessions

• Completion and presentation of a workplace improvement project

• Successful completion of a final exam demonstrating applied knowledge

Learning Objectives

Participants will learn to:

• Apply Lean and Six Sigma principles to real operational challenges

• Use structured problem-solving and project management techniques

• Identify waste, reduce variation, and improve process performance

• Lead improvement projects with moderate analytical complexity

• Collect, analyze, and interpret process data

• Connect improvement results to business performance

Syllabus Overview

1. Lean and Six Sigma Foundations

• Introduction to Lean: Purpose, People, Process

• Customer Value and the Eight Wastes

• Lean Principles and Continuous Improvement

• Six Sigma Overview and the Cost of Poor Quality (COPQ)

• Rolled Throughput Yield and the Hidden Factory

• Problem-Solving Methodology: DMAIC

• Project Scoping using A3S

2. Define Phase

• Defining the problem and setting project scope

• Project Charter and SMART Goal Definition

• Team roles and stakeholder engagement

• SIPOC diagrams and baseline performance metrics

3. Measure Phase

• Process understanding through mapping (flow, swim lane, value stream)

• Identifying hidden inefficiencies

• Failure Modes and Effects Analysis (FMEA)

• Data collection planning and defect analysis

• Measurement system considerations

• Basic capability analysis

4. Analyze Phase

• Root cause identification through data analysis

• Hypothesis testing and visual data exploration

• Using tools such as 5 Whys, Pareto charts, and cause-effect diagrams

• Verifying true root causes with data

5. Improve Phase

• Developing and testing countermeasures

• Lean tools: 5S, Standard Work, Visual Management, Error Proofing

• Flow principles, Just-in-Time, and workplace layout

• Prioritizing improvements using an XY Matrix

• Gap analysis and future state design

• Piloting solutions and refining through PDCA

6. Control Phase

• Sustaining results with control plans and process monitoring

• Introduction to control charts

• Leader Standard Work and process confirmation

• Embedding improvements through management systems

Intended Audience

This course is intended for professionals in manufacturing, operations, logistics, and supply chain roles who are responsible for improving process performance and delivering measurable results through hands-on project work.