Six Sigma Green Belt Certification and Lean Training
Syllabus

Session One - Six Sigma Introduction

• Principles and Philosophy of Lean and Six Sigma
• Evolution of Quality Approaches
• Six Sigma with Lean and TOC
• Statistical Definition of Six Sigma
• Six Sigma Measures
• Roles of Six Sigma Players - GB, BB, Masters, Champions
• Customer Performance Measures
• Using Metrics (Variable Stratification)
• Metrics & Customer Dissatisfaction

Session Two – Lean Introduction

• Murphy’s Toys –
• The House of Toyota
• Additional Lean Considerations
• Correcting the Eight Deadly Waste
• Lean Transformation
• Lean Readiness Assessment 

Session Three - The Solving Process

• What is DMAIC
• Applying DMIAC
• A DMAIC Case Example
• Selecting a SS DMAIC Project (Team Concept)
• Process Mapping
• Types of Process Mapping
• SIPOC Diagram
• Process Flow Chart
• VSM

 Session Four - The Lean Culture

• A Vision for Lean
• Employee Involvement in lean
• A Vision for Lean
• Lean Teams
• Jidoka
• Murphy’s Toys Pilot Product Family
• Action Plan
• Vocabulary Check
• Progress Check
• Learning Objectives Review

Session Five- Data Collection

• What's Statistics
• The Scientific Method
• Fears about Stats
• Uncertainty
• Stats of Problem Solving
• Terms
• Types of Stats
• Types of Data
• Measurements
• Types of Designed Studies

Session Six - Value Stream Mapping

• Introduction to Current-State Mapping
• Lean Concepts and Improvements for the Future State
• VSM Drives CI
• Product/Process Matrix for Murphy’s Toys
• Preparing to Map Murphy’s Toys
• Current State VSM
• Take Time and Pitch
• Improvements for the Future State
• Can the Process Match Demand?
• Finish Goods Strategy
• Improving Flow
• FIFO
• Pull Systems
• Schedule One Point
• Intervals
• Review Future State Map for Murphy’s Toys

Session Seven - Six Sigma Metrics

• Measuring the Current State
• Defect Types Breakdown
• Current State Metrics
• Quality Yield
• Defect per Million (DPM)
• Defects per Million Opportunities (DPMO)

Session Eight- Stable and Process Improvement

• Looking back at Murphy’s Toys VSM
• Achieving Demand Stability
• Achieving Process Stability
• Load Leveling
• Mixed-Model Production
• Buffering with Inventory
• Safety Stock
• Buffering with Labor
• Buffering with Backlog
• Causes of Process Variability
• Standard Work
• TPM
• Six Sigma Applications
• Continuous Improvement
• Setup Opportunities
• 5S
• Eliminate Waste
• Simplify Operations

Session Nine- Seven Basic Quality Tools

• Process Maps
• Check Sheets
• C & E Diagrams
• Histograms
• Scatter Diagrams
• Control Charts

Session Ten – Just-in-Time

• Customer Demand
• Standard Work
• Flow and Balance
• Implement Pull
• Develop Schedules

Session Eleven - Descriptive Stats

• Discrete & Continuous Measurements
• Sample vs. Population
• Types of Descriptive Stats
• Location, Mean, Median, Mode
• Dispersion: Range, Standard Deviation, Variance
• Stats Software

Session Twelve – Measuring

• Comparing Assumptions
• Comparing What is Important
• Metrics
• Lead Time
• Future State Actions
• Lean Accounting
• Murphy’s Toys Lean Metrics
• Aligning Objectives with Measurements

Session Thirteen - Stratification Analysis and Data Patterns

• What is Stratification Analysis?
• Frequency Analysis Tools
• Frequency Table
• Histograms
• Dot Plot
• Understanding Data Patterns
• Shapes
• Outlier
• Box Plot
• Single Box Plot
• Multiples Box Plot

Session Fourteen – Sustaining

• Designing Products for Lean
• Design for Manufacture and Assembly
• Traditional vs.
• Reducing then Bill of Material
• QFD
• Design Change Control
• FEMA (Failure Mode and Effects Analysis)
• Final Design and Process Planning
• Strive for Perfection
• Six Sigma DMAIC and PDCA
• Sustains Impact of :Lean
• Seven Quality Tools Game

Session Fifteen - Process Capability Indices and Correlation Analysis

• Types of Capability Indices
• Exclude Centering: Cp, Pp, CR
• Include Centering: Cpk, Ppk
• Making Sense of Capability Indices
• Process Improvement Strategies
• Correlation Analysis
• Within Product Correlation Analysis
• Product/Process Correlations
• Product/Product Correlations
• Scatter Plot (X - Y Graph)
• Simple Linear Regression
• R Factor
• R2 (R squared) Factor
• Regression Trappings/Misinterpretations

Session Sixteen - The Voice of the Customer, Surveys, and Fundamentals of SPC

• VOC
• Surveys
• Survey Writing Tips & Errors
• Fundamentals of SPC
• Teaching Hitting
• Target Practice
• Cause of Variation
• Funnel Experiment
• Shewhart's Contribution
• A Case Study
• Key Control Charts Issues
• Pattern Recognition
• Basic SPC Steps

Session Seventeen- Understanding Yield Stats

• FTT/FTY
• Final Yield
• Throughput Yield
• Rolled Throughput Yield
• Normalized Yield

Six Sigma Green Belt Training - FEES & REGISTRATION