Lean Sigma & Six Sigma Training with Smallpeice Enterprises

LEAN SIGMA MANUFACTURING GREEN BELT

Commences October 11th(Leamington Spa)	Ł2400+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 Ł175 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
October 11th	October 12th	October 13th	October 14th
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
October 26th	October 27th	October 28th	October 29th
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
November 1st	November 2nd	November 3rd	November 4th
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