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Six Sigma Green Belt

4 Days or 8 4-hour Modules

This course is targeted toward developing Six Sigma process improvement project leaders.  It provides a background on the Six Sigma methodology and covers the tools and techniques necessary for implementing a successful process improvement culture in your organization.  Students will be asked to bring a “live” process improvement project and supporting data to class where we will develop a clear project definition, conduct data analysis using inexpensive tools that require basic Excel knowledge and get a great start on an actual project.  Upon completion of the course, an exam and a project, students will qualify for a Six Sigma Green Belt certification.  This course can be delivered in eight 4-hour modules or four full days (two sessions per day).  Between sessions, students will have homework that will be reviewed at the beginning of the next session.

Session One
• Introduction to Six Sigma Methodology
• History of Six Sigma
• How is Six Sigma different from Total Quality or other Quality programs?
• What is Six Sigma?
• Value of Six Sigma
• How does it work?
• Key elements of Six Sigma
• Approaches to Six Sigma
• The project selection process – when to use each approach
• Key organizational drivers and metrics
• Organizational goals and Six Sigma projects
• Enterprise strategy
Session Two
• LEAN concepts and tools
• Value stream mapping
• Identifying value-added and non-value added activities
• Theory of constraints
• Design for Six Sigma (DFSS) in the organization
• How does Quality Function Deployment fit in the DFSS process?
• Road maps for DFSS
• Introduction to DMAIC (Define-Measure-Analyze-Improve-Control)

Session Three – Define
• Process elements – define and describe process components and boundaries
• Owners and stakeholders – the Voice of the Customer
• Identifying and analyzing customers
• Using the SIPOC
• Methods for collecting customer feedback
• Analyzing customer feedback
• Translating feedback into requirements – CTQ (Critical to Quality)
• Developing the project charter and problem statement
• Defining the project scope

Session Four – Define (Planning) and Measure
• Introduction to management planning tools
• Defining team roles and responsibilities for a Six Sigma project team
• Team stages and dynamics
• Project planning
• Project risk analysis
• Communication techniques and documentation
• Defining key project metrics
• Calculating process performance metrics – COPQ, DPMO, Yield
• Team tools
• Process modeling – “as is”

Session Five – Measure
• Collecting and summarizing data
• Types of data and measurement scales
• Data collection methods
• Assuring data accuracy and integrity
• Populations and samples – when to use each
• Central limit theorem and sampling distribution
• Measures of dispersion and central tendency
• Probability concepts and distributions
• Interpreting diagrams
• Measurement system analysis

Session Six – Measure and Analyze
• Process capability studies
• Process performance vs. specification
• Process capability indices
• Process performance indices
• Short-term vs. long-term capability
• Computing the Sigma level
• Applying sampling plans
• Multi-vari studies
• Interpret correlation coefficient and its statistical significance
• Basics of hypothesis testing
• Tests for means, variances and proportions
• Paired-comparison tests
• ANOVA – Analysis of variance
• Chi Square

Session Seven – Improve and Control
• Introduction to Improve
• Design of experiments
• DOE Terms
• Interpreting main effects
• Implement and validate solutions
• Statistical Process Control – objectives and benefits
• Understanding how rational subgrouping is used
• Deliverables Review
• Validate Savings
• COPQ Review
• Introduction to Control

Session Eight – Control and Closeout
• Selection and application of control charts
• Analysis of control charts
• Control Plan Key Deliverables
• Control Plan Components
• Transition Plan Execution
• Project Close Out
• Exam Review
• Wrap up