Lean Six Sigma

Lean Six Sigma

Six Sigma is a combination of tools and strategies for process improvement originally developed by Motorola in 1986. Six Sigma became very popular after General Electric made Six Sigma a central focus of their business structure in 1995. The Six Sigma goal is to improve the quality of processes by identifying and removing the causes of defects (errors) and minimizing variability in manufacturing and business processes. Six Sigma uses a set of quality management methods and creates an infrastructure of people within the organization (Black Belts, Green Belts, Orange Belts, etc.) who are experts in these quality process methods. Each Six Sigma project carried out within an organization follows a defined sequence of steps and has quantified financial targets (cost reduction and/or profit increase). Following Six Sigma principles have saved companies millions of dollars and driven profit to their bottom lines. Thousands of companies have implemented Six Sigma, spanning across multiple industries like the military, government, financial services, healthcare, sales, operations, human resources, technology, food and beverage, manufacturing and bio-tech. By training with New Horizons, individuals can select a project or process to improve and achieve impactful results through training.

Courses

  1. Lean Six Sigma White Belt
  2. Lean Six Sigma Yellow Belt
  3. Lean Six Sigma Orange Belt
  4. Lean Six Sigma Green Belt
  5. Lean Six Sigma Black Belt

Lean Six Sigma White Belt

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Overview

In this course, students will identify the fundamental concepts of Six Sigma.

Who Should Attend

This course is intended for all professionals from entry-level individuals, experienced individuals, and various levels of management.

Duration

Classroom Learning – 1 Day(s)

Prerequisite(s) or Equivalent Knowledge:

Six Sigma – Introduction

At Course Completion

Upon successful completion of this course, students will be able to: – discuss the basics of Six Sigma. – describe a Six Sigma organization. – examine the Six Sigma approach. – identify the DMAIC methodology. – implement Six Sigma.

Course Outline

Lesson 1: Getting Started with Six Sigma

  • Describe Six Sigma
  • Define Quality
  • Identify Key Metrics of Six Sigma

Lesson 2: Describing a Six Sigma Organization

  • Determine the Need for a Customer-Driven Organization
  • Identify a Six Sigma Organization

Lesson 3: Examining the Six Sigma Approach

  • Identify Six Sigma Methodologies
  • Identify Six Sigma Projects

Lesson 4: Identifying the DMAIC Methodology

  • Describe the Define Phase
  • Describe the Measure Phase
  • Describe the Analyze Phase
  • Describe the Improve Phase
  • Describe the Control Phase

Lesson 5: Implementing Six Sigma

  • Identify the Essentials of Six Sigma Implementation
  • Implement Six Sigma
  • Assess Six Sigma Implementation

Lean Six Sigma Yellow  Belt

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Overview

In this course, students will identify the fundamental concepts of Lean Six Sigma.

Who Should Attend

This course is intended for any level of employee and various levels of management that intend to take an active role in the Lean Six Sigma methodology.

Duration

Classroom Learning – 1 Day(s)

Prerequisite(s) or Equivalent Knowledge:

Six Sigma – Introduction

At Course Completion

Upon successful completion of this course, students will be able to: – describe the basics of Lean Six Sigma. – describe a Lean Six Sigma organization. – conduct Lean Six Sigma DMAIC phase 1: the Define phase. – conduct Lean Six Sigma DMAIC phase 2: the Measure phase. – conduct Lean Six Sigma DMAIC phase 3: the Analyze phase. – conduct Lean Six Sigma DMAIC phase 4: the Improve phase. – conduct Lean Six Sigma DMAIC phase 5: the Control phase. – describe the implementation of Lean Six Sigma.

Course Outline

Lesson 1: Fundamentals of Lean Six Sigma

  • Describe Lean Six Sigma
  • Identify the Elements of Six Sigma
  • Identify the Elements of Lean
  • Relate Lean Six Sigma to Other Quality Methodologies

Lesson 2: Describing a Lean Six Sigma Organization

  • Determine the Need for a Customer-Driven Organization
  • Identify CTQs from the VOC
  • Identify Lean Six Sigma Projects
  • Identify Lean Six Sigma Teams and Roles in an Organization
  • Identify Lean Six Sigma Methodologies

Lesson 3: Conducting Lean Six Sigma DMAIC Phase 1: The Define Phase

  • Describe the Define Phase
  • Draft a Project Charter
  • Draft an SIPOC Diagram

Lesson 4: Conducting Lean Six Sigma DMAIC Phase 2: The Measure Phase

  • Describe the Measure Phase
  • Create a Process Map
  • Create a Fishbone Diagram
  • Create the Cause and Effect Matrix
  • Gather Data

Lesson 5: Conducting Lean Six Sigma DMAIC Phase 3: The Analyze Phase

  • Describe the Analyze Phase
  • Perform Basic Statistical Calculations
  • Perform Correlation
  • Create a Value Stream Map
  • Identify Wastes in a Process
  • Perform Process Value Analysis
  • Perform Pareto Analysis

Lesson 6: Conducting Lean Six Sigma DMAIC Phase 4: The Improve Phase

  • Describe the Improve Phase
  • Establish a Pull System
  • Generate Ideas for Solutions
  • Assess Risks
  • Pilot Solutions

Lesson 7: Conducting Lean Six Sigma DMAIC Phase 5: The Control Phase

  • Describe the Control Phase
  • Draft a Process Management Plan
  • Perform SPC

Lesson 8: Describing the Implementation of Lean Six Sigma

  • Identify the Essentials of Lean Six Sigma Implementation
  • Describe Lean Six Sigma for Service Organizations
  • Describe DMAIC Failure Modes

Lean Six Sigma Orange Belt

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Overview

Lean Six Sigma Orange Belts are knowledgeable in the field of Basic Problem Solving and are familiar with Lean Six Sigma methodologies and tools. Orange Belts are improvement project team leaders within their direct work environment and provide constructive contributions to larger Lean Six Sigma Green/ Black Belt projects. 

Who Should Attend

Operators, managers, supervisors and engineers directly or indirectly involved in process improvement programs. 

Duration

Classroom Learning – 4 Day(s)

Prerequisite(s) or Equivalent Knowledge:

Six Sigma – Introduction

At Course Completion

On completion of the Lean Six Sigma Orange Belt training, you will be familiar with Lean and Six Sigma methodologies as well as the most important tools, conce
pts and abbreviations within Lean Six Sigma. You will learn what Lean Manufacturing and Six Sigma can do for your company. You will also learn how to solve production problems in an effective manner.

Language

This training is available in English or Dutch

Course Outline

  • Lean principles (Value, Value Stream, Flow, Pull, Continuous Improvement)
  • Lean simulation game & Lean Six Sigma case (DMAIC)
  • Voice of the Customer & CTQ Flowdown
  • Measuring Process Performance (Yield, DPMO, ppm, ..)
  • SPC – Statistical Process Control
  • MSA – Measurement System Analysis / Gage R&R%
  • FMEA – Failure Mode Effect Analysis
  • 5S Workplace organisation
  • VSM – Value Stream Mapping
  • Identifying and eliminating waste
  • Visualising data / Introduction to Minitab
  • (Pareto, Bar Chart, Pie Chart, Dot Plot, Histogram, Box Plot, Time Series Plot, Scatter Plot)
  • Problem solving tools (Pareto, Cause & Effect, Capability, …)
  • Basic Statistics (Correlation, Regression, Probability, …)
  • Kaizen Continuous Improvement / PDCA

 


Lean Six Sigma Green Belt

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Overview

Students will implement Six Sigma as a Green Belt.

Who Should Attend

This course is intended for any level of employee and various levels of management that intend to take an active role in the Six Sigma methodology.

Duration

Classroom Learning – 5 Day(s)

Prerequisite(s) or Equivalent Knowledge:

Six Sigma – Introduction

At Course Completion

Upon successful completion of this course, students will be able to: –

  • Discuss the basics of Six Sigma
  • Identify Six Sigma methodologies.
  • Describe the fundamentals of the Define phase.
  • Describe the fundamentals of project management.
  • Apply management and planning tools used across the DMAIC methodology to identify opportunities for improvement.
  • Identify key metrics of a Six Sigma project.
  • Describe team dynamics.
  • Identify the basic concepts related to the Measure phase.
  • Perform basic probability and statistical calculations.
  • Describe the data collection plan.
  • Describe descriptive measures of statistics.
  • Use graphical methods to depict process performance.
  • Analyze and interpret a measurement system’s capability.
  • Conduct process capability and performance studies.
  • Describe the fundamentals of the Analyze phase.
  • Conduct hypothesis testing.
  • Conduct the Six Sigma Improve phase.
  • Describe the Control phase of the DMAIC methodology.
  • Describe SPC.
  • Describe the implementation of Six Sigma.

Course Outline

Lesson 1: Fundamentals of Six Sigma

  • Describe Six Sigma
  • Identify Organizational Drivers and Metrics
  • Describe Project Selection and Organizational Goals
  • Describe Lean

Lesson 2: Identifying Six Sigma Methodologies

  • Describe the DMAIC Methodology
  • Describe the DFSS Methodology
  • Describe QFD
  • Describe DFMEA and PFMEA

Lesson 3: Conducting the Six Sigma Define Phase: Introduction

  • Describe the Define Phase
  • Describe Process Elements
  • Identify Stakeholders and Process Owners
  • Identify Customers
  • Gather Customer Data
  • Analyze Customer Data
  • Translate Customer Requirements
  • Identify Six Sigma Projects

Lesson 4: Conducting the Six Sigma Define Phase: Fundamentals of Project Management

  • Draft a Project Charter
  • Develop the Project Scope
  • Identify Project Metrics
  • Identify Project Planning Tools
  • Describe Project Documentation
  • Describe Project Risk Analysis
  • Describe Project Closure

Lesson 5: Co
nducting the Six Sigma Define Phase: Management and Planning Tools

  • Create an Interrelationship Digraph
  • Create a Tree Diagram
  • Create a Prioritization Matrix
  • Describe a Matrix Diagram
  • Draft a PDPC
  • Create an Activity Network Diagram

Lesson 6: Conducting the Six Sigma Define Phase: Key Metrics of Projects

  • Track Process Performance
  • Perform FMEA

Lesson 7: Conducting the Six Sigma Define Phase: Team Dynamics

  • Describe Six Sigma Team Stages and Dynamics
  • Describe Six Sigma Teams and Roles
  • Identify Team Tools
  • Identify Effective Communication Techniques

Lesson 8: Conducting the Six Sigma Measure Phase: Introduction

  • Describe the Measure Phase
  • Draft a SIPOC
  • Create a Process Map
  • Describe Additional Process Documentation Tools
  • Create a Fishbone Diagram
  • Create a Cause-and-Effect Matrix

Lesson 9: Conducting the Six Sigma Measure Phase: Probability and Statistics

  • Describe Basic Probability Concepts
  • Identify Valid Statistical Conclusions
  • Describe the Central Limit Theorem

Lesson 10: Conducting the Six Sigma Measure Phase: The Data Collection Plan

  • Identify Data Types
  • Identify Data Collection Methods
  • Identify Sampling Types

Lesson 11: Conducting the Six Sigma Measure Phase: Descriptive Measures

Lesson 12: Conducting the Six Sigma Measure Phase: Graphical Methods

  • Create a Run Chart
  • Create a Box-and-Whisker Plot
  • Create a Stem-and-Leaf Plot
  • Create a Scatter Plot
  • Create Pareto Charts

Lesson 13: Conducting the Six Sigma Measure Phase: Measurement System Analysis

  • Perform Measurement System Analysis
  • Conduct the Gage R&R Study
  • Interpret Gage R&R Data

Lesson 14: Conducting the Six Sigma Measure Phase: Process Capability and Performance

  • Determine Process and Customer Specification Limits
  • Conduct a Process Capability Study
  • Interpret Process Capability
  • Interpret Sigma Levels

Lesson 15: Conducting the Six Sigma Analyze Phase: Introduction

  • Describe the Analyze Phase
  • Perform Multi-Vari Studies
  • Perform Simple Linear Correlation
  • Perform Simple Regression

Lesson 16: Conducting the Six Sigma Analyze Phase: Hypothesis Testing

  • Introduction to Hypothesis Testing
  • Conduct Hypothesis Tests
  • Perform t-Tests
  • Perform Single-Factor ANOVA
  • Perform Chi-Square Tests

Lesson 17: Conducting the Six Sigma Improve Phase

  • Describe the Improve Phase
  • Perform DOE
  • Interpret Main Effects and Interaction Plots
  • Generate Ideas for Solutions
  • Pilot Solutions

Lesson 18: Conducting the Six Sigma Control Phase: Introduction

  • Describe the Control Phase
  • Draft a Control Plan

Lesson 19: Conducting the Six Sigma Control Phase: SPC

  • Describe Control Charts
  • Create Control Charts
  • Interpret Control Charts
  • Implement and Validate Solutions
  • Six Sigma Project Closure

Lesson 20: Describing the Implementation of Six Sigma

  • Identify the Essentials of Six Sigma Implementation
  • Describe Six Sigma for Service Industries
  • Describe DMAIC Failure Modes

Lean Six Sigma Master Black Belt

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Overview

The Lean Six Sigma Master Black Belt program allows students to complete certification requirements faster than traditional Lean Six Sigma training programs. This course combines combines Six Sigma Methodology and Lean Thinking.

Who Should Attend

This course is designed for business professionals with a college degree or those professionals who have significant experience in business operations. Also invited to attend are students who have completed a Black Belt program through an external vendor or through an in-house program.

Duration

Classroom Learning – 5 Day(s)

At Course Completion

Requirements for Master Black Belt Certification:

  1. Attend Master Black Belt Training
  2. Complete the Black Belt test with an 85% or higher score.
  3. Write a white paper

This proposal is based upon the following

  • Certification awarded
  • Maximum 8 hours training per day
  • The above price is Exclusive of VAT
  • This proposal will be valid for 30 days
  • Scoring Criteria for Evaluation
  • New Horizons will give room for clarifications during assessment.

Course Outline

Lesson 1: Strategic Planning

  • Strategic Planning Tools
  • Interviews and Data Gathering
  • Competitive Benchmarking
  • Corporate Alignment
  • Business Performance Measures
  • Hoshin Kanri

Lesson 2: Governance and Infrastructure

  • Six Sigma Roles and Responsibilities including Process Owners and Champions
  • Steering committees, Resource allocation,
  • Training Models and Traps, Certification, Green Belt, Black Belt, and Champion Mentoring
  • Rewards and Recognition

Lesson 3: Change Management

  • Change Management Execution
  • Organizational Readiness Assessment
  • Branding and Marketing the Initiative, Creating a Burning Platform
  • Stakeholder Analysis, Influence Strategies, Communication
  • Organizational Change and Cultural Change Strategies

Lesson 4: Process Management

  • Process Leveling
  • Establishing Process Metrics /Key Process Indicators (KPI’s)
  • Cost of Poor Quality, Cost-Benefit Analysis, Return on Investment
  • Lean Six Sigma Program Management (Tollgate Reviews, Annual Review)

Lesson 5: Project Selection and Oversight

  • Project Selection Criteria, Project Prioritization, and Project Scope
  • Project Mentoring, Team Facilitation, Group Dynamics,
  • Project Results, Project Replication and Project Intervention

Lesson 6: Additional Improvement Methods

  • DFSS, DMADV, LEAN concepts
  • Theory of Constraints
  • Process Re-Engineering and TQM

Lesson 7: Master Black Belt Test