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PROGRAMME OVERVIEW |
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This
programme is designed to provide delegates with an
integrated approach for
improving the flow, capability and consistency of
manufacturing processes, thereby reducing waste, increasing
customer satisfaction and improving business performance.
The robust ‘DMAIC’ approach provides a common structure for
improvement, within
which a wide range of techniques can be applied.
Improvement projects undertaken
by delegates are a key feature of this Green Belt programme,
enabling them to ‘learn by
doing’, and providing an immediate return for their
companies.
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PROGRAMME OBJECTIVES |
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To develop a clear understanding of
value, waste & process variability
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To ensure that the essential foundations
are in place for successful Lean Sigma deployment
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To provide a truly integrated, structured
improvement methodology
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To introduce a range of techniques for
improving process flow and efficiency, & reducing
variability within manufacturing processes
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To ensure the sustainability of process
improvements To achieve significant improvements during the
training programme
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PROGRAMME CONTENT |
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BLOCK 1 |
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Day 1 |
Day 2 |
Day 3 |
Day 4 |
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Introduction to Lean Sigma
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Programme
introduction
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Objectives & origins of Lean Sigma
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The value of an integrated approach
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Understanding value, waste & process variability
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Developing a Lean Sigma improvement strategy &
implementation plan
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Policy deployment & performance measurement
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Lean Sigma Foundations
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Building a sustainable CI improvement culture
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5S workplace organisation
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Creating a visual workplace
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Daily management
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Structured approaches to improvement
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Sources & types of manufacturing Problems: flow &
consistency
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The DMAIC approach – a single structure
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Lean
Sigma roadmap & toolkit
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DMAIC Structured Improvement Methodology
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DMAIC improvement exercise
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Defining & scoping the problem
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Mapping,
measuring & assessing processes
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Analysing
the facts & finding the root causes
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Improving
the process with creative solutions
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Implementing,
sustaining & replicating the gains
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Reviewing
performance
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Initiating Lean Sigma Projects
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Project identification, scoping & selection
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Project planning & getting started
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Project reviews & support
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Measuring project success
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Action planning
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Block 1 assessment, summary & review
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BLOCK 2 |
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Day 5 |
Day 6 |
Day 7 |
Day 8 |
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Measuring Process
Variability
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Analysing Process Variability
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Statistical analysis techniques
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Introduction to hypothesis testing
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Introduction to regression analysis
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Identifying key process input variables using Design of
Experiments (DOE)
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Improving & Controlling Process
Variability
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Improving process performance
using DOE
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Introduction to screening
techniques & Taguchi experiments
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Controlling
process variability using SPC control charts
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Leadership & Change Management
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Managing
organisational change
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The dynamics & process of change
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Building commitment to change
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Leading, building & coaching effective improvement teams
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Action
planning
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Block 2 assessment, summary & review
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BLOCK
3 |
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Day 9 |
Day 10 |
Day 11 |
Day 12 |
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Value Stream Mapping & Improving Process Flow
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Using the DMAIC process to improve process flow
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Introduction to Value Stream Mapping
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Drawing
& evaluating the current state map
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Lean
techniques for improving process flow
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Creating
the future state map
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Developing
the improvement plan
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Improving Overall Equipment Effectiveness
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Measuring
& improving Overall Equipment Effectiveness
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Total
Productive Maintenance (TPM)
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Implementing
autonomous maintenance
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Rapid
Changeover Techniques (SMED)
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4-Step
changeover reduction
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Changeover improvement activity
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Mistake Proofing & Cellular Manufacturing
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Achieving zero defects with Mistake Proofing (Poka Yoke)
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Mistake Proofing in manufacture, design & the office
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Factory layout & cellular manufacturing
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Introduction to lean supply chains
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Factory
simulation & improvement activity
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Project Closure & Sustainability
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Project closure & sign-off
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Building
sustainability (process audits, ongoing performance reviews
etc)
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Green
Belt certification requirements: final project reports &
presentations
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Action
planning
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Block
3 assessment, summary & review
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BLOCK
4 |
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Day 13 |
Day 14 |
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On-Site Project Review
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Certification Event
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ACCREDITATION |
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This programme includes an accreditation process that
includes a project, multi-choice examination and project
presentation. |
