Six Sigma – Green Belt

Introduction

Six Sigma is a well-recognized process improvement methodology based on statistics, originally developed by Bill Smith of Motorola and later applied by GE. Its objective is to bring down the number defects from the current levels to less than 3.4 defects per million parts. It can be applied equally well for products or services and is particularly suited for manufacturing operations involving large number of repetitive parts. Its objectives are to reduce waste, improve quality/yield and save money.

Six Sigma (also written as 6 s where s stands for the Greek letter sigma, which is used as a symbol for “Standard Deviation”) is associated with the normal distribution curve, which generally describes variability in nature and many activities.

The methodology is usually abbreviated as DMAIC (Define, Measure, Analyze, Improve, Control).

Course Overview

Six Sigma Green Belt program, participants will gain knowledge and skills of the DMAIC approach, along with statistical tools to quantify process performance. Six Sigma work requires active participation from Green Belts on a project team. Your training will build on previous training and teaches numerous responsibilities. These include project management techniques, organization and standardization skills, as well as quality management tools. Additionally, you will develop key skills for Six Sigma work. These include defining a Six Sigma project, using basic tools for project definition and process baseline. You will also learn how to perform data analysis and assess measurement system capabilities.

Participants who successfully complete a Six Sigma training program are usually awarded a Green Belt, Brown Belt or Black Belt (along the lines of Japanese martial arts like Judo and Karate), depending on the size and scope of the project they undertake, and the quantum of savings achieved. By assigning projects to them during or immediately after the training, their employers can expect to show savings and improvement in the bottom line. Intangible benefits include greater employee engagement and motivation and a positive mindset.

The Six Sigma approach is popular in a wide cross-section of industries around the world and a certification in Six Sigma is accorded a high degree of respect in most organization. 

Who can attend?

Operation Managers, Team Leads, QA Manager, Professionals seeking lead improvements in their work areas, Manufacturing Managers, Engineers

Learning Outcome

After completing the training, participants will be able to

• Understand the Six Sigma concepts and their application in process and product development
• Formulate the problem in a manner that facilitates its resolution
• Identify what data will be relevant to analyze the problem, gather it and arrange it systematically
• Develop skills required to predict defects ahead of time and make plans while taking preventative measures for quality control
• Analyze the data using Excel or statistical tools such as Minitab
• Arrive at ways to improve the process to reduce defect occurrence
• Put in place controls to maintain the improved process

Duration: 5 days

Prerequisite: None

Mode of Delivery: Trainer led Virtual session

Course Outline

The Six Sigma Green Belt curriculum focuses on:

Introduction to Six Sigma

Six Sigma Success Stories, The Sigma Level, the 99.9% problem, calculating the sigma level – tool set, DNA of a Champion, Framework, DMAIC, Process mapping

Define I – The Value Stream

Introduction to define, process thinking, the source of value, value stream leverage, process mapping, SIPOC, flow charts, spaghetti charts, Value stream mapping tool set, Pareto chart tool set, Pareto chart, project selection, project charter, project tracking tool set

Define II – Voice of the Customer

Introduction to voice of the customer, focus on the customer, understanding customer requirements, conducting surveys, Structuring Survey Questions, The degree of uncertainty in sampling, guideline for margin of error, affinity diagram, CTQC (Critical to Quality Characteristics) tree diagram, operational definition, voice of the customer as specifications

Measure I – Introduction to Measurements

Introduction measure, measurements, discrete vs continuous measurements, measurement subjects, as a process, the analysis of measurement systems, Gage R&R (Repeatability and Reproducibility), MSA (Measurement System Analysis) – Graphing, Attribute Measurement System Analysis, Calibration of Measurement System, collecting data, developing a sampling plan, baseline performance, derivative performance metrics, throughput yields, rolled throughput yields, the sigma level revisited

Measure II – Charting Process

Introduction to Measure II, trend chart, histogram, quantifying process variability, Statistical Process Control – Introduction to control charts, limits, Implementing SPC, SPC Chart Selection, Rational Sub grouping, X- and Moving Range Charts, Attribute Control Chart, X-bar and R Chart Related Theory, Process Capability

Analyze I – Possible Root Cause

Introduction to Analyze, finding the root cause, cause & effect diagram, 5-Why, 1-How, Combination of 5-Why, Pareto and Trend Chart, Scatter Plot, Correlation and Regression Analysis, Factors in determining sample size, estimating population mean.

Analyze II – Hypothesis Testing

Introduction to Hypothesis testing, process on trial, the hypothesis – accept or reject? Types of error, hypothesis testing, confidence intervals, treatment comparisons-control charts, Z test, t-test.

Analyze III – DOE (Design of Experiments)

Design of experiments – introduction, components, purpose, process, blocking, blocking and tackling

Improve

Introduction to improve, Design for Six Sigma (DFSS), Bench marking, brainstorming, FMEA, error proofing, continuous flow, quick changeover, pull scheduling, corrective action matrix, Simple Linear Regression, Multiple Regression Analysis (MRA).

Control

Introduction to control, the process control plan, visual control, 5-S Approach, Total Productive maintenance (TPM) Objectives & Benefits.

The training comprises Highly participative and interactive group discussions, practical exercise, critique sessions, handouts, course templates and case studies

We also provide Six Sigma – Foundation course for 3 days