
Lean and Six Sigma have evolved in Toyota, Japan and Motorola, USA respectively. Lean has a reputation of making the organization to drive cost reduction through creating an organization wide war on waste. Lean makes the organization competitive in the longterm. On the other hand, Six Sigma proved itself as the most effective problem solving approach and delivers breakthrough results in the shortterm.
An organization can gain both in shortterm and longterm by combining the Lean as well as Six Sigma approaches. Lean Sigma program combines the best of American and Japanese quality management practices.
ISLcertified Lean Six Sigma Green Belts learn the six sigma problems solving methodology (DMAIC), the statistical tools and Lean tools. The focus is to master the application skills rather than learning the theoretical understanding. The program makes extensive use of MSExcel for data analysis.
Learning Objectives
 To understand the philosophy of Six Sigma
 To learn DMAIC methodology and application of various statistical tools
 To be able to lead Six Sigma Green Belt projects.
 To understand the basic concepts, tools and practices of Lean
 To learn tactical skills for implementing lean at specific process.
 To be able to explain the lean concepts to the team
 To be able to apply lean principles to different process settings
Methodology
This training and certification is delivered completely online. The Learning Management System (LMS) provides following elements:
Multimedia lecture (Audio lectures with automatic slide transition)
Quiz, with correct answers and explanations for the wrong answers.
Discussion forum for engaging in dialogue with other participants.
StepbyStep project guidance
Course Content
The course is based on BodyofKnowledge of IQF, USA and SME, USA:
 Six Sigma Concept & Philosophy
 Six Sigma Concepts and Philosophy
 Six Sigma Deployment
 Metrics: DPU,DPMO, RTY
 Champion, Black Belt and Green Belts
 Selecting Projects
 Define and Measure Stage
 Define Stage: Creating Project Charter, Identifying Customers & Their Needs and Requirements, Creating SIPOC
 Measure Stage: Identifying CTQs, Selecting Sampling Strategy and Collect the data, Establish the Baseline Performance
 Basic Statistics: Concept of Variation, Data Types; Normal, Exponential, Binomial, Poisson distributions, Measures of central tendency  Mean, Median, Mode, Measures of Dispersion  Range, Standard deviation, Variance, Central Limit Theorem
 Visualization Techniques: Process Mapping, Quality Function Deployment (QFD)
 Measurement System Analysis: Types of errors in Measurement System, R&R for Variable measurement, R&R for Visual Inspection
 Analyze Stage
 Analysis Stage : Sources of variation, Identifying root cause and Validation
 Data Analysis: common and special causes of variation, Control charts, Xbar and Range Chart, Individual and Moving Range Chart, Histogram, pchart, cchart, Pareto analysis, Precontrol charts
 Process Capability: Cp, Cpk, Pp, Ppk
 Cause Analysis: Cause and Effect diagram, WhyWhy analysis.
 Diagnostic Techniques: MultiVari chart, Paired comparison
 Improve Stage
 Improving Stage: Generating Potential Solutions, Select the Best One, Developing MistakeProof Measures, Process Optimization, Validating the Results
 Advanced Statistics: Sampling distribution, Estimation, Hypothesis Testing, ANOVA, Correlation and Regression
 Design of Experiments (DoE): Fractional Factorial designs, Full Factorial designs.
 Control Stage
 Control Stage: Defining the Process Control System, Modifying the Documentation System, Conducting Training, Institute the Process Audit System, Quantifying the Gains
 Control Plans
 Failure Modes and Effects Analysis (FMEA).
 Team Working
 Origin and Philosophy Lean
 Mass production vs Lean
 Muda, Mura, Muri
 Seven Types of Wastes
 Valueadded Activity
 Lean Manufacturing House
 Lean thinking Mode
 Operational Stability
 Indicators of Stability
 Strategies for stability
 Standards and Visual Control
 5S, Redtagging, Spaghetti diagram
 TPM, Six Big losses, quasiproblems
 Standard Work
 Standardization – benefits, prerequisites, people focus
 3 elements of standard work
 Takt time, work sequence, inprocess stock
 Charts for standardized work – production capacity chart, standardized work combination table, standardized work analysis chart, job element sheet
 Individual and overall efficiency, manpower reduction
 kaizen and layouts
 JustinTime
 Little’s law
 Push system, large lot production
 Pull system, basics of JIT
 Continuous Process Flow, one piece flow
 Push scheduling, Kanban, Pacemaker process,
 Six Kanban Rules, types of kanbans
 Conveyance, Hejunka, Changes in demand
 Types of pull – Type A, B and C
 Jidoka
 Autonomation
 Zeroquality control
 Types of Inspection – Judgment, Informative, Source, Vertical, horizontal
 Three aspects of Poka yoke – Actions, Paths and Methods of detection
 Andon
 Involvement
 Goal involvement
 Types of Kaizen teams – Kaizen Circle Activities, Practical Kaizen Training
 Roles, Responsibilities of members, facilitators, managers etc.
 Kaizen Leadership
 Suggestion scheme – measurement, motivation
 Problem Solving
 A3 Problem Solving
 Introduction
 Problem Situation
 Target
 Theme
 Cause Analysis
 Countermeasures
 Implementation
 Followup
 IQF Lean Six Sigma BoK
 Distributions
 Statistical Inference & ANOVA
 Measurement Assurance
 SPC
 Process Capability
 Regression
 Lean Metrics
 Inventory Theory
Certification Criteria
IQFLean Six Sigma Green Belt certification is awarded on completion of the following:
Complete 13 learning modules
Score 60% or more in quiz at the end of each learning module
Score 50% or more in IQFLean Six Sigma Green Belt exam
Complete one Lean Six Sigma Project (Optional)
Registration
Register online at www.isl.co.in and pay Fee Rs 29,214/ (for students in India) and Rs 47,740/ (for students outside India) through Credit Card,bank transfer, Demand Draft or Cheque (in favour of Institute of Sigma Learning Pvt. Ltd, Hyderabad). You will receive the course material within 10 working days.
