Lean Six Sigma Training & Seminars

  • Overview

    Lean Six Sigma is a business improvement methodology that maximizes shareholder value by achieving the fastest rate of improvement in customer satisfaction, cost, quality, process speed, and invested capital. The fusion of Lean and Six Sigma improvement methods is required because:

    • Lean cannot bring a process under statistical control.
    • Six Sigma alone cannot dramatically improve process speed or reduce invested capital.
    • Both enable the reduction of the cost of complexity.

    Ironically, Six Sigma and Lean have often been regarded as rival initiatives. Lean enthusiasts note that Six Sigma pays little attention to anything related to speed and flow, while Six Sigma supporters point out that Lean fails to address key concepts like customer needs and variation. Both sides are right. Yet these arguments are more often used to advocate choosing one over the other, rather than to support the more logical conclusion that we blend Lean and Six Sigma.

  • White Belt

    Concepts and methodologies are explained and illustrated. Participants learn about value streams, waste, and basic lean tools as well as data collection and the interpretation of the data, specifically as it relates to the processes. A portion of this class will be dedicated to a discussion of how health care organizations apply the tools and methods in support of robust performance.

    Topic Highlights:
    • Introduction to Lean
    • Value
    • Value Stream Mapping
    • Waste
    • 5S
    • SMED
    • Six Sigma Projects
    • Variation
    • Healthcare Applications
     
    • Six Sigma philosophy
      • Objective
      • Organization
      • Structure
      • Approach
      • DMAIIC
    • Histograms/Basic Statistics
    • Statistical Process Control
    Training Objectives:
    • Define a plan for implementing Lean Six Sigma in your organization
    • Interpret the nature of the variation found in all processes
    • Identify and eliminate waste within operations
    • Recognize the DMAIIC model used to improve processes
    • Explain the Lean Six Sigma methodology and the benefits of a Lean Six Sigma program

  • Lean Six Sigma Green Belt

    This seminar, the introductory course in Lean Six Sigma, will give you a thorough understanding of Lean Six Sigma and its focus on eliminating defects through fundamental process knowledge. Topics covered in addition to DMAIIC, lean, and Six Sigma philosophy, include basic statistics, value stream mapping, statistical process control, waste reduction, process capability, financial implications and root cause analysis.

    Overview:

    Learn how to integrate principles of business, statistics, waste reduction, and engineering to achieve tangible results. Master the use of Lean Six Sigma to quantify the critical quality issues in your company. Once the issues have been quantified, lean and six sigma analysis, including statistics can be applied to provide probabilities of success and failure. Lean and Six Sigma methods increase productivity and enhance quality. As a Lean Six Sigma green belt, you will be equipped to support and champion Lean Six Sigma implementation in your organization. To earn the Lean Six Sigma Green Belt Certificate, you will be required to pass IIE's Lean Six Sigma green belt exam.

    Prior seminar participants have reported significant savings from implementing their projects.

    • A financial services organization saw $128,000 in cost savings per quarter when they reduced transaction processing rework
    • An aerospace manufacturing organization saved over $100,000 by reducing waste
    • A state agency reduced project cost over-runs by 28 percent
    • A transportation company saved more than $875,000 per year in turnover costs by improving the employee communications process
    • Reduced errors in a painting operation led to increased first pass acceptance and more than $197,000 in annual savings
    • A Web developer increased annual profits by 10 percent by cutting cycle time
    • A wave solder operation saw defects reduced by half and costs reduced by $60,000 per year
    Topic Highlights:
    • Basic statistics
    • Value Stream Mapping
    • Cycle Time Reduction
    • DMAIIC
    • Financial implications
    • Process capability
    • Root cause analysis
    • 5S
    • Six Sigma process and objective
    • Statistical process control


    Training Objectives:
    • Design and develop Lean Six Sigma projects
    • Determine process capability
    • Employ the DMAIIC process
    • Perform basic statistical analysis on process measurements
    • Prepare root cause and cause effect analysis
    • Support and champion Six Sigma implementation in your organization
    Course Content
    • Lean Six Sigma - Overview and the DMAIIC Process
    • Team Effectiveness - Learn key team effectiveness and project management tools to ensure the success of your projects: Building high-performing teams, team launch, facilitating meetings, communications/effective listening, RACI charts, managing conflict, project management
    • Gate Reviews and the role of the Green Belt in a Lean Six Sigma project
    • Voice of the Customer and Kano Analysis - Collecting customer information, customer- focused business strategy, converting VOC into CTQ, developing customer surveys, specifying and classifying customer requirements
    • Basic Tools - Brainstorming, Cause and Effect Diagram, Nominal Group Technique, Affinity Diagram, Force-field Analysis, Pareto Chart, Multivoting
     
    • Process Mapping - SIPOC, Value Stream Mapping, Swim Lane Chart, Process Flow Charts, Top-down Flow Chart
    • Introduction to Variation and Basic Statistics - Normal Distribution, Measures of Central Tendency (Mean, Median, Mode), Measures of Variation (Variance, Standard Deviation, Range), histograms
    • The Value of Cycle Time - Relationship of Cycle Time, WIP, and Throughput (Little's Law), Cycle Time in Traditional vs. Lean Operations, Define Process Cycle Efficiency, How to Measure Cycle Time
    • Control Charts - Special Cause vs. Common Cause Variation, Types of Control Charts (Average, Range, Moving Range, Individuals, P-charts), Interpreting and applying control charts
    • Waste Reduction
    • 5S

  • Lean Six Sigma Black Belt

    The Lean Six Sigma Black Belt four-week program is designed for experienced Six Sigma practitioners with a Green Belt Certification (or equivalent process improvement experience) who wish to achieve the pinnacle of lean Six Sigma training by developing critical skills for leadership in enterprise wide deployment.

    Overview:

    Lean techniques eliminate wasteful activities, while Six Sigma is a disciplined method for meeting customers' expectations and eliminating defects in any process. IIE's Lean Six Sigma Training offers the unique approach of weaving both lean and Six Sigma methodologies into a seamless certificate program that can help you achieve substantial improvements in your organization.

    By completing this course of study, you will gain a solid general knowledge of the theory, composition and implementation of a lean Six Sigma initiative. You will also become proficient in all of the analytical tools necessary to define, measure, analyze, improve, implement and control improvement projects.

    Topic Highlights:
    • Hands-on simulation
    • Inventory strategies
    • Lean and Six Sigma as a business strategy
    • Lean as a component of strategy
    • Six Sigma as a component of strategy
    • Lean planning
    • Supplier integration
    • Configure to demand: How to move toward a multitiered product delivery system
    • Process flow: Establish flow and make it lean
    • Pull from customer through supply: Reduce customer wait times
    • Rate-based planning: Plan resources necessary for a lean environment
    • Business process managements
    • Computer applications
    • Design of experiments (DOE)
     
    • Design for Six Sigma (SFSS)
    • DMAIIC
    • Enterprisewide deployment
    • A3
    • Takt time
    • Cycle time
    • Loading diagrams
    • Standard work
    • Process control
    • Project management
    • Regression and correlation modeling
    • Statistical methods and sampling
    • Statistical process control
    • Team processes
    • Leading kaizen events
    Training Objectives:
    • Configure to demand
    • Develop lean process flows
    • Implement lean in your organization
    • Reduce cycle time through minimizing wait times
    • Analyze process data using comprehensive statistical methods
    • Control the process to assure that improvements are used
    • Define an opportunity for improving customer satisfaction
    • Implement the recommended improvements
    • Improve existing processes by reducing variation
    • Measure process characteristics that are critical to quality

    Course Content
    • Projects
    • Go 'Configure to Demand' - A look at how to move toward a multitiered product delivery system using:
      • Product Configuration
      • Planning Bills of Materials
      • Product Delivery System Integration Techniques
    • Learn the Process Flow - A look at how to establish flow and how to make it lean using lean process design techniques:
      • Baseline Process
      • Product Anatomy
      • Process Anatomy
      • Activity Level Data Collection
      • Lean Design
      • Data Analysis
      • New Process Design (Flow, Point of Use, Pull, Quality, Takt)
      • Lean Tools (e.g. Point of Use and Visual Controls)
    • Rate-based Planning - A look at how to plan the resources necessary for operating in a lean environment using:
      • Schedule Cycle and Footprint
      • Mix Model Sequencing
      • Sequencing and Pacing Box
      • Capacity Planning and Response Profiles
     
    • Pull from Customer Through Supply - A look at how to reduce customer waiting time significantly and increase customer satisfaction using:
      • Finished Goods Inventory Strategies
      • Point of Sale Data
      • Production Planning
      • Material Control
      • Kanban
    • Accomplish supplier and logistics integration
    • Complete a lean enterprise transformation
    • Develop a multi-tiered product delivery system
    • Identify the components of a lean process
    • Integrate rate-based planning and scheduling
    • Project Management
    • Team Skills
    • Six Sigma Philosophy and Structure
    • Introduction to Statistics
    • Descriptive
    • Confidence and Confidence Intervals
      • Means
      • Standard Deviations
      • Proportions
     
    • Probability and Probability Distributions:
      • Definitions
      • Rules
      • Hypergeometric
      • Binomial
      • Poisson
      • Normal
      • Exponential
      • Chi Square
      • F
      • Student t
    • Tests of Hypothesis
      • Means
      • Standard Deviations
      • Proportions
    • Design of Experiments
      • Concepts
      • ANOVA
      • Factorial
    • Statistical Process Control and Process Capability
      • Variables
      • Attributes
    • Process Capability
    • Reliability
    • Measurement Systems Analysis
    • Goodness of Fit Testing
    • Regression and Correlation
      • Linear
      • Curvilinear
      • Multivariate
    • Cost of Quality
    • Exam