Lean Six Sigma Green Belt – process improvement and quality management

Training process

Training needs analysis

If you have specific requirements regarding the training programme, we will carry out a training needs analysis for you. This will guide us on which aspects of the programme should receive greater emphasis, so that the training programme meets your specific needs.

What will you gain?

You combine Lean and Six Sigma - You will learn how to combine waste elimination with process variation reduction, so you can choose actions that truly improve quality, lead time and operating costs.

You define projects clearly - You will learn how to build a project charter, describe a business problem, set success metrics and turn customer requirements into clear improvement objectives.

You map processes end to end - You will practice SIPOC, process mapping and identifying critical points, so you can quickly see where delays, errors and losses are created across the workflow.

You analyze data with confidence - You will learn how to collect and validate data, assess the measurement system and use descriptive statistics and trend analysis to make decisions based on facts.

You find root causes - You will use 5 Whys, Ishikawa, Pareto and FMEA in practice, so you can separate symptoms from real causes and set better priorities for improvement actions.

You design effective improvements - You will develop solutions using Kaizen, 5S, standard work, Visual Management, Poka-Yoke, SMED and kanban to implement changes that hold up in daily operations.

You sustain the results - You will learn how to build standards, monitor KPIs and use SPC control charts, so you can detect deviations earlier and prevent old problems from returning.

You lead a Green Belt project - You will practice the full project path from Define to Control, including progress reporting and presenting results, to prepare for leading improvement initiatives on your own.

Training programme

1. Introduction to Lean Six Sigma

philosophy of continuous improvement:
- origins of Lean Management and Six Sigma,
- business benefits resulting from implementing Lean Six Sigma,
- the role of Green Belt in the organization,
- linking Lean Six Sigma with the company's strategy,
basic concepts and terminology:
- value for the customer (VOC – Voice of Customer),
- waste (Muda), overburden (Muri), unevenness (Mura),
- process variation and quality,
- PDCA and DMAIC cycle.

2. Defining improvement projects (Define)

identification of problems and areas for improvement:
- selection of Green Belt projects,
- formulation of the business problem,
- defining project objectives,
- determining success metrics,
stakeholder analysis and customer requirements:
- identification of process customers,
- collection and analysis of requirements,
- Voice of Customer (VOC),
- Critical to Quality (CTQ),
Management of the improvement project:
- project charter (Project Charter),
- structure of the project team,
- roles and responsibilities,
- planning of project activities.

3. Process Mapping and Analysis (Measure)

business process modeling:
- SIPOC,
- end-to-end process mapping,
- process flow diagram,
- identification of critical points,
measurement of process efficiency:
- key performance indicators (KPI),
- definition of the measurement system,
- collection of process data,
- data visualization,
measurement systems analysis:
- introduction to MSA,
- accuracy and repeatability of measurements,
- sources of measurement errors,
- data validation.

4. Analysis of problem causes (Analyze)

analysis of process data:
- descriptive statistics,
- data distributions,
- trend analysis,
- identification of deviations,
root cause identification tools:
- Ishikawa diagram,
- 5 Why method,
- Pareto analysis,
- cause-and-effect relationship diagram,
analysis of risk and quality problems:
- FMEA (Failure Mode and Effects Analysis),
- process risk assessment,
- prioritization of improvement actions,
- determining the areas of greatest impact.

5. Process improvement (Improve)

designing improvement solutions:
- generating improvement ideas,
- creative problem-solving techniques,
- Kaizen workshops,
- assessment of solution feasibility,
Lean tools supporting improvements:
- 5S,
- work standardization,
- Visual Management,
- Poka-Yoke,
- SMED – reducing changeover times,
- kanban and pull systems,
implementing changes:
- improvement implementation plan,
- change management,
- communication with stakeholders,
- monitoring implementation effects.

6. Sustaining results (Control)

building sustainable improvements:
- process standardization,
- process documentation,
- process audits,
- organizational knowledge management,
monitoring effectiveness:
- SPC control charts,
- process indicators system,
- monitoring process stability,
- early detection of deviations,
managing continuous improvement:
- change sustainment mechanisms,
- culture of continuous improvement,
- the role of leaders and process owners,
- subsequent improvement initiatives.

7. Lean Six Sigma project management

Green Belt project organization:
- DMAIC project management methodology,
- scheduling activities,
- project risk management,
- progress reporting,
teamwork and communication:
- building team engagement,
- conducting project workshops,
- conflict resolution,
- presentation of project results.

8. Practical workshops

analysis of real processes:
- mapping of the selected process,
- identification of losses and inefficiencies,
- analysis of the causes of problems,
- development of corrective actions,
Green Belt project:
- preparation of the project charter,
- analysis of process data,
- development of the improvement plan,
- presentation of recommendations and results.

9. Green Belt Exam and Certification

verification of acquired competencies:
- Lean Six Sigma Green Belt knowledge test,
- evaluation of the practical project,
- discussion of the most common errors,
- preparation for independently conducting improvement projects.

What are the prerequisites for participating in the training?

Understanding of company processes - You should understand how at least one process works in your organization, so you can more easily analyze workflow, quality issues and points where losses occur.

Basic data literacy - You should be able to read simple reports, indicators and charts, so you can take part effectively in process data analysis and the interpretation of measurement results.

Teamwork experience - You should have experience working with other people in operational or project settings, because the course includes workshop activities and strong communication elements.

Readiness to improve processes - You should be ready to analyze problems, challenge current ways of working and propose changes, because the course focuses on practical process improvement.