1.1.5 - LEAN SIX SIGMA GREEN BELT

Objective:

The course has as central point to teach the methodology Lean Six Sigma at the GB level, in a manner, that the practitioner uses it to generate the necessary changes in the organization. The approach is of easy and applied use of the tool in industrial environments. It puts the analytical tools of the Six Sigma (DMAIC) together with the easiness and speed of the Lean tools, aiming the GB to have more success in the generation of changes over the process. As it is applied to operations, the approach is to put main tools for execution in manufacturer environments.

In short:

• To associate and execute the Lean Six Sigma methodology
• Why and when to utilize the Lean Six Sigma model
• To utilize the Lean Six Sigma methodology to obtain significant results in the improvement of on-going Process, Products or Services.
• Lean Six Sigma X Financial Impact in the organization.
• To develop Leadership Competencies for the introduction and management of the changes in the organization.
• To build a culture of Business Efficient Management in the company, creating a perception of increased market value for the stakeholders.

Target-Audience:

• Professionals from diverse working areas that desire to know and apply the Lean Six Sigma (DMAIC flux) methodology for the improvement of processes.

Pre requirements:

• There are not impeditive pre-requirements for the training. It is suggested that the practitioners have the profile to lead project teams and be engaged by the challenge of promote changes in the organization.

Course Duration:

• 80 hours. In general, the training happens in two separated weeks (one per month) in a manner that the GB develops his project together with his training.

Programmatic Content:

WEEK 1

Introduction

• Six Sigma definition
• Six Sigma review
• DMAIC flux
• Process view
• Introduction to the Lean
• Lean principles
• The eight wastes of the Lean
• The association of Lean with Six Sigma – why does it bring advantages for us?
• Lean Six Sigma structure

Define

• Introduction to define Phase
• Indentifying Projects
• Financial impact of the projects and relation with the EVA (Economic Value Added)
• Metrics deployment – QFD – Quality Function Deployment
• Value Chain Map
• Identification of the customer needs – voice of the customer/ voice of the process
• Defining project metrics
• Scope definition – Matrix: it is and it is not / SIPOC
• Project charter

Measure

• Introduction to Measure Phase
• Process Map
• Up time / Down Time / Takt Time
• Cause & Effect Diagram (Fishbone)
• Cause & Effect Matrix
• Effort X Impact Matrix
• Data Type (Continuous and Discrete)
• Basic Statistic – position measurements, variation measurements and normal curve
• Data Collection – Planning (Operational definition)
• Measurement System Analysis (MSA) – Continuous and discrete data.
• Basic graphs – Pareto / Box Plot / Dispersion Diagram / Trend
• Capability analysis – Continuous Data (Normal data)
• Capability analysis -  Discrete data
• OEE (Overall Equipment Efficiency)
• FTT (First Time Through) / RTY (Rolled Throughput Yeld) – Process yield indexes
• Project reviews and in-class presentation
• Assessment

WEEK 2

Analyze

• Introduction to Analyze Phase
• Statistical Analysis Map
• Hypothesis Test (Comparison among  means, medians and variation using: ANOVA, 1 – Sample-T, 2-Sample-T, F-Test)
• Simple and Multiple Regression analysis
• Chi-Square, 1-Proportion and 2-Proportion tests

Improve

• Introduction to Improve Phase
• Action Plans Generation – 5W2H
• Change Management
• Fast Set Up
• 5S
• Standard Operation
• Physical Place With Rationalized Fluxes
• Operation Cells
• Labour Flexibility
• Kaizen event
• DOE (Design of Experiments) – Full Factorial

Control

• Introduction to Control Phase
• Control Process System and Control Plan (BPMS)
• Mistake Proofing Devices
• Process Standardization
• Statistical Process Control (SPC) for Continuous Data
• Statistical Process Control (SPC) for Discrete Data
• Project reviews and in-class presentation

Presentation of Projects

Test

Training Modalities

• In Company – Carried out in Closed Classes, by customer request

Requirements for Certification:

• This Training is only provided in-company. Thus, the certification depends of the customer requirements. In general, the standard to be followed is.
  1 – Development of one project with impact in the organization
  2 – At least 80% of frequency in the training.
  3 – At least 70% of success in the activities carried out during the training.

OBS: All participants earn the conclusion certificate if comply with 80% of frequency in the training.

Specific Needs for Training Attendance:

• Computers – should be one for each three attendants
• Use of Minitab statistical software