Lean Six Sigma Green Belt Body of Knowledge

1) Overview of Lean Sigma

Industry Snippets

What is Lean Six Sigma

Why is it so successful

Lean vs. Six Sigma

When to use Lean or Six Sigma and When not to use

When do Individuals and Organizations Fail using Lean and Six Sigma?

2) Perspectives of Lean Six Sigma

Historical Perspective

Mean vs. Variation

Quantitative Perspective

Statistical Perspective

Customer Perspective

Operational Perspective

3) Recognize Phase

Strategic Priorities

Core / Non-core Process Identification

SWOT of Core Process

Customer Complaint Analysis

VRIO Analysis of Strengths, Weaknesses and Opportunities

Business Perceptions and Feedback

Matrix b/w Strategic Competitive Edge and Impact to Strategic Priorities

4) Define Phase

Obtaining Voice of Customers (VOC) (Surveys,

Focus Groups, Interviews, Customer complaints, etc.)

Converting VOC to CTS / CTQ

9-3-1-0 Analysis of CTQs

Defining CTQ Targets (USL & LSL)

Defining CTQ Tolerance Limit

CTQ Drill Down Chart

Team Charter

Defining Business Case

Defining Problem Statement

Defining Goal Statement and Estimated Benefits

Defining Financial Impact

Defining Project In-Scope

Defining Project Out-of-Scope

Defining Constraints i.e. Conflicting CTQs

Mapping to Strategic Priorities of Company

Defining Project Sponsor

Defining Process Owner

Defining Lean Six Sigma Mentor or Coach

Defining Lean Six Sigma Black Belt / Green Belt

Defining Team Members (RACI Matrix)

Schedule Definition for DMAIC completion

COPIS

Value Stream Mapping

5) Measure Phase

Sampling vs. Population

Statistics vs. Parameter

Descriptive Statistics vs. Inferential Statistics

Sampling (Random, Stratified, Systematic, etc.)

Sample Size Determination

Defining Segmentation Factors of CTQ

Measurement System Analysis of CTQ

Operational Definition of CTQ and Segmentation Factors

Defining Data Collection Plan for CTQ and Segmentation Factors

Histogram of CTQ and Study of Histograms

Normality Test of CTQ

Mean, Median, Mode

Standard Deviation, Range, Variation Measures for Non-normal data

Defining measure of Central Tendency and Variation

Z value calculation and practical applications

Calculating Process Capability (Zmin, Cpk)

Z-Shift

Process Capability
Process performance vs. specification (Diff. between natural process limits and s
pecification limits, and calculate process performance
metrics such as percent defective, parts per million (PPM), defects per million op
portunities (DPMO), defects per unit (DPU),
process sigma, rolled throughput yield (RTY), etc.)

Defining Improvement Goals

Updating Goal Statement and Financial Impact

Time Value Map

Descriptive Statistics and Graphical Representation (Pie Chart, Bar Chart, Box Pl
ots, Histograms, Pareto Charts, Scatter Plots, Run charts)

6) Analyze Phase

Control Charts & Identification of Special Causes and Warning Signals in Commo
n Causes

Correlation and Regression Analysis (correlation coefficient)

Check sheets

Cause Effect Diagrams / Fish Bone Diagrams; 4 types:

Dispersion Analysis

Cause enumeration

Production process classification

Cause Effect Matrix

Pareto Chart

Run chart

Cross Functional Flowchart

Requirements Review

Threads of Similarity

Opportunities of Error

FMEA (RPN, PFMEA, DFMEA)

Seven Deadly Wastes (MUDA)

Kaizen & Kaizen Blitz

Kaikaku

Continuous Flow

Pull Production: Just in Time

Pull Production: Kanban

Visual Management

Heijunka: Leveling

Heijunka: Sequencing

Heijunka: Standardization

Jidoka / Autonomation

5S: Sort

5S: Set in Oder

5S: Shine

5S: Standardize

5S: Sustain / Systemize

Poka Yoke: Elimination

Poka Yoke: Replacement

Poka Yoke: Facilitation

Poka Yoke: Detection

Poka Yoke: Mitigation

Benchmarking

Benchmarking: Metrics Benchmarking

Benchmarking: Process Benchmarking

7) Improve Phase

PEST Analysis

Decision Matrix

Effort Impact Matrix

Force Field Analysis

Pilot Plan

8) Control Phase

Process Control Plan

PTAP (Project Transition Action Plan)

Sustain Improvements (Lessons learned, Training plan Deployment, Documentat

ion, Ongoing Evaluation)

Project Closure

Project Sign-off