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MANUFACTURING

Overview

Yellow Belt

Green Belt

Black Belt Upgrade

Black Belt

Master Black Belt

in-company only:

Champion

Project Selection

BUSINESS

Overview

Green Belt

Black Belt Upgrade

in-company only:

Black Belt

LEAN SIGMA™

Overview

Green Belt

DESIGN FOR SIX SIGMA

Overview

in-company only:

    Modular Programme

LEAN CONVERSION

Lean Conversion

SOFTWARE COURSES

Introduction to Minitab

LEAN SIGMA MANUFACTURING GREEN BELT

PROGRAMME OVERVIEW

This programme fully integrates Lean and Six Sigma to provide an improvement model
that concentrates on both reducing cycle time and variability. Lean tools are linked to
the robust DMAIC problem-solving approach, and focus on analysing processes,
customer demand, and product flow - producing fast and visual process improvements.
Six Sigma techniques are applied throughout the improvement process to provide
robust data analysis, measurement and creative solutions required to reduce complex
variability in product and processes.

PROGRAMME FORMAT

Our new public programme is based on a 12-day modular format which combines
training inputs, practical simulation activities, with an ongoing focus on project
progress and reviews. Delegates are expected to enter the programme with a
suitable Lean Sigma project assigned, and will progress live improvement activity
in parallel with training – leading to formal certification as a Green Belt. In-company
private programmes follow a similar model but can be adjusted in content and duration
to match specific company requirements.

COACHING & SUPPORT

Smallpeice can provide an expert coaching support for individual delegates or
    company teams. This service includes formal review and support of project work,
    facilitating live Lean Sigma events on the factory floor, and providing a 1-to-1 mentoring
    support for key projects or delegates.

The programme is also supported by an exclusive ‘Lean Sigma Support Site’ which is
    a web-based application allowing Green Belts to access soft copy templates,
    supporting information, with the additional option to access remote coaching via
    personal work areas and assigned coaches.

FEE PACKAGES

Public Course £3,900 + VAT per delegate
Private Course: quotation on application

PROGRAMME CONTENT

BLOCK 1: LEAN SIGMA ESSENTIALS

May 12

May 13

May 14

May 15

Introduction to Lean Sigma

Programme Introduction

Objectives & Origins of
    Lean Sigma

The Value of an
    Integrated Approach

Understanding Value,
    Waste & Process
    Variability

Developing a Lean Sigma
    Improvement Strategy &
    Implementation Plan

Policy Deployment &
    Performance
    Measurement

Lean Sigma Foundations

Building a Sustainable
    Continuous Improvement
    Culture

5S Workplace
    Organisation

Creating a Visual
    Workplace

Daily Management

Structured Approaches to
    Improvement

Sources & Types of
    Manufacturing Problems:
    Flow & Consistency

The DMAIC Approach – a
    Single Structure

The Lean Sigma Roadmap
    & Toolkit

DMAIC Structured Improvement Methodology

DMAIC Improvement
    Exercise

Defining & Scoping the
    Problem

Mapping, Measuring &
    Assessing Processes

Analysing the Facts &
    Finding the Root Causes

Improving the Process
    with Creative Solutions

Implementing, Sustaining &
    Replicating the Gains

Reviewing Performance

Initiating Lean Sigma Projects

Project Identification,
    Scoping & Selection

Project Planning &
    Getting Started

Project Reviews &
    Support

Measuring Project
    Success

Action Planning

Block 1 Assessment,
Summary & Review

Delegates implement project improvement activity @ workplace

BLOCK 2: FOCUS ON FLOW

June 17

June 18

June 19

June 20

Value Stream Mapping & Improving Process Flow

Using the DMAIC
    Process to Improve
    Process Flow

Introduction to Value
    Stream Mapping

Drawing & Evaluating the
    Current State Map

Lean Techniques for
    Improving Process Flow

Creating the Future State
    Map

Developing the
    Improvement Plan

Leadership &
Change Management

Managing Organisational
    Change

The Dynamics & Process
    of Change

Building Commitment to
    Change

Leading, Building &
    Coaching Effective
    Improvement Teams

Action Planning

Mistake Proofing & Cellular Manufacturing

Achieving Zero Defects
    with Mistake Proofing
    (Poka Yoke)

Mistake Proofing in
    Manufacture, Design &
    the Office

Factory Layout & Cellular
    Manufacturing

Introduction to Lean
    Supply Chains

Factory Simulation &
    Improvement Activity

Improving Overall Equipment Effectiveness

Measuring & Improving
    Overall Equipment
    Effectiveness

Total Productive
    Maintenance

Implementing Autonomous
   Maintenance

Rapid Changeover
   Techniques

4-Step Changeover
    Reduction Method

Changeover Improvement
    Activity

Block 2 Assessment, Summary & Review

Delegates implement project improvement activity @ workplace

BLOCK 3: FOCUS ON CONSISTENCY

July 15

July 16

July 17

July 18

Measuring Process Variability

Using the DMAIC
    Process to Improve
    Process Variability

Basic Statistics

Introduction to Minitab

Measurement System
    Analysis (R&R Studies)

Graphical Analysis

Capability Analysis

Analysing Process Variability

Statistical Analysis
    Techniques

Introduction to Hypothesis
    Testing

Introduction to Regression
    Analysis

Identifying Key Process
    Input Variables using
    Design of Experiments
    (DOE)

Improving & Controlling Process Variability

Improving Process
    Performance using DOE

Introduction to Screening
    Techniques & Taguchi
    Experiments

Controlling Process
    Variability using SPC
    Control Charts

Project Sustainability

Project Closure & Sign-
    Off

Building Sustainability
    (Process Audits, Ongoing
    Performance Reviews,
    etc)

Green Belt Certification
    Requirements: Final
    Project

    Reports & Presentations

Action Planning

Block 3 Assessment, Summary & Review

On-site Project Review

Project Review at Delegate’s Workplace

Coaching & Support for Final Report & Presentation

Certification Event

Final Project Presentations