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LEAN SIGMA MANUFACTURING GREEN BELT

 

Commences January 8th '13 (Leamington Spa)

2400+VAT per delegate

inclusive of:

  • Comprehensive training manual

  • Lunches and refreshments

  • Lean Sigma Toolkit

  • Access to Lean Sigma Website

4book places

     

INTRODUCTION

This programme integrates Lean and Six Sigma to provide a powerful improvement model that concentrates on both reducing cycle time and variability. The programme is based on a modular format which combines training inputs and practical simulation activities with an ongoing focus on project progress and reviews. The training objectives focus on enabling delegates to:

  • lead projects that deliver tangible organisational benefits

  • be familiar and confident with the key tools and techniques of Lean Sigma and understand how to use them within day-to-day activities

  • be effective team members on any Lean Sigma project team

ACCREDITATION

The Smallpeice accreditation process for Lean Sigma Green Belts incorporates completing a project for formal assessment and passing a multi-choice examination.

BQF Accreditation Option: Smallpeice courses are also licensed for BQF (British Quality Foundation) accreditation, enabling candidates to achieve this external accreditation benchmark. The accreditation steps are as described above, with an additional 250 fee to cover the licensed accreditation route (Note: more details on accreditation options will be provided in Block 1).

 

BLOCK 1

Defining the
Problem

Understanding the
Current State &
 Introduction to Statistics

Data Collection Planning &
 Measurement
Systems Analysis

Leading
Effective Change

January 8

January 9

January 10

January 11

Programme Introduction

  • Programme Objectives & Certification Routes

  • Improvement Project Roles and Responsibilities

 

Improvement Roadmap

  • Introduction to the DMAIC roadmap

  • Pre-requisites for successful projects

  • Project selection criteria

  • Application of the DMAIC toolkit in daily work

 

The Define Phase

  • Writing problem statements

  • Setting the project objectives

  • Scoping the project the concept of y =f (x)

  • Mapping the high level process SIPOC mapping tool

  • Linking the problem to the voice of the customer

  • Defining critical to quality characteristics

  • Drawing up the project charter

 

Understanding the Current State

  • Introduction to the Measure Phase

  • Detail Process flow charting techniques

  • Taking a proactive approach to identifying weaknesses in the current process

  • Use of failure mode effects analysis (FMEA) to identify potential opportunities for defects

  • Evaluating, reducing & managing risk

 

Introduction to Statistical Concepts & Minitab

  • Introduction to basic statistics and their context in Lean Sigma projects

  • Learning to describe data -measures of location, variation and shape

  • Communicating statistics to a non-technical audience

  • Introduction to Minitab software

 

Data Collection Planning

  • Understanding different types of process variation

  • Selecting what to measure

  • Key considerations for data collection planning

  • Deciding how to collect the data: an introduction to sampling techniques

  • Completing a data collection plan

  • Writing effective operational definitions for data collection

 

Measurement Systems Analysis

  • Checking the measurement system

  • Understanding measurement system variation

  • An introduction to Gauge Repeatability and Reproducibility

  • Gauge R & R in Minitab

 

Preparing and Planning for Change

  • Understanding the nature of change

  • Analysing enablers and barriers to change

  • Analysing and managing stakeholders

  • Understanding the role of the project sponsors

  • Writing an effective communication plan

Leading Process Change

  • Barriers & enablers to team effectiveness

  • Influencing for change

 

Facilitating Improvement Activities with Teams

  • Identifying activities

  • Organising your team & stakeholders

  • Facilitation Skills

 

Contracting for Success

  • Review next steps

  • Action Planning

 

BLOCK 2

Analysing the
Value Stream Current State

Optimising the Effectiveness of Critical Equipment Designing a
Lean Future State
Barriers to
Creating Flow & Implementing the Future State

February 5

February 6

February 7

February 8

Understanding the Current Value Stream

  • Defining value streams

  • Organising by value stream

  • Developing the current state Map

  • Mapping transactional processes

 

Analysing the Current State

  • Balancing load and capacity

  • Finding and analysing bottlenecks

  • Cycle time and workload analysis

  • Work in process and Lead time analysis

 

Introduction to Total Productive Maintenance

  • Objectives of TPM

  • Measuring Overall Equipment Effectiveness

  • Autonomous maintenance

  • Developing TPM standards

 

Rapid Changeover

  • The concepts of SMED

  • Internal vs external work

  • Recording the changeover process

  • Techniques for converting internal  to external

  • Changeover simulation activity

  • The Concept of Jidoka

 

Steps for Creating a Future State Map

  • Creating a Lean Vision

  • Developing a 'must be' list

  • Step by Step guide to developing the future state map

  • Strategies for Creating Continuous Flow

  • Push versus Pull Systems

 

WIP Control Strategies

  • Material Flow Control

  • Use of Kanban and CONWIP systems

 

Developing the Improvement Plan

  • Identifying manning and skills requirements

  • Developing the improvement plan

 

Barriers to Developing Flow

  • Dealing with fluctuations in customer demand

  • Dealing with physical constraints

  • Dealing with non repetitive work & creating flow

  • Scheduling non repetitive work flows

 

Creativity Techniques

  • The role of creativity in Lean Thinking

  • Barriers to creative thinking

  • Creative Thinking Tools

  • Links to Future State mapping

 

Facilitating Value Stream Mapping Activity

  • Planning mapping activity

  • On the day dealing with facilitators nightmares

  • After the event implementing and sustaining the improvement

 

BLOCK 3

Analysing Performance & Verifying Root Causes

Optimising the Process

Designing the
Future State & Sustaining
the Improvements

March 5

March 6

March 7

March 8

Taking a Structured Approach to the Analyse Phase

  • Introduction to the analyse phase

  • 5 Why Approach to problem solving

  • Forming and testing hypotheses

  • Writing an analysis plan

 

Visualising the Data

  • What shape is your data? Histograms

  • Visualising Descriptive Statistics Graphical Summary Tool

  • Understanding confidence limits

 

Assessing Process Control

  • What is happening over time? Time Series Plots

  • Understanding process control

  • Anatomy & use of Control charts

  • Applications of SPC Charts

 

Assessing Process Capability

  • Understanding process capability

  • Calculating process capability for Continuous and Attribute Data

  • Selecting appropriate capability metrics & indices

  • Dealing with non-normal data

 

Verifying the Root Cause

  • Link to cause and effect diagram

  • Stratifying the data use of box plots

  • Are there any relationships? - Scatter Diagrams

  • Where are the biggest opportunities? - Pareto

  • Links to project storyboard hints and tips for summarising and presenting the analysis

  • Introduction to significance testing approach

 

Introduction to Regression Analysis

  • Understanding correlation

  • Introduction to simple linear regression

  • Application in Lean Sigma Projects

 

Optimisation Processes:
Design Of Experiments

  • Introduction to designed experiments (DOE)

  • Applications of DOE techniques

  • Basic system optimisation

  • Screening techniques using DOE

  • Optimising a worked example

Improve Phase: Solution Generation & Piloting

  • Challenges of the Improve Phase

  • Generating alternative solutions

  • Evaluating and selecting the best solution

  • Piloting & solution introduction

 

Solution Introduction  & Control 

  • Developing a control plan

  • Prevention & detection systems

  • Choice of control method

  • Out of control action planning

  • Handover & transferring benefits

  • Planning for continuous improvement

 

Contracting for Success

  • Project reviews, lessons learnt & next steps

 

 

Commences January 8th '13 (Leamington Spa)

2400+VAT per delegate

inclusive of:

  • Comprehensive training manual

  • Lunches and refreshments

  • Lean Sigma Toolkit

  • Access to Lean Sigma Website

4book places

     

Smallpeice Enterprises Limited 2012