1. Welcome to Lean Six Sigma Green Belt Training
Congratulations on being selected for Green Belt training.
Green Belt training will consist of 2 weeks of formal training.
General Electric, Allied Signal, Motorola, and many other organizations have saved billions through their Six Sigma programs. The Lean Six Sigma curriculum will provide an expanded set of tools which will further enhance your ability to deliver significant value to the Army.
Lean Six Sigma is not a statistics course.
Lean Six Sigma is an improvement initiative in which resources (Black Belts and Green Belts) are armed with a powerful set of problem solving tools (Six Sigma and Lean) and sent into the organization to form, lead, and mentor teams on solving complex, high return projects.

2. Welcome to Lean Six Sigma Green Belt Training (Cont.)
The following slides will provide a high-level view of what to expect from your training.
Please remember that Lean Six Sigma is first and foremost a process. We only apply tools when they meet our objectives.
Many tools will be taught, and it will be up to the Green Belt along with the team to decide when and where to apply the Lean Six Sigma tools.
It is the goal of this training program to educate the students on the application of the Lean Six Sigma Improvement Process and the intelligent, strategic use of the Lean Six Sigma tools.
Tool use guidance will be given and discussed in class.

3. Lean Six Sigma DMAIC Improvement Process Road Map
Define
Measure
Analyze
Control
Improve
Activities
Identify Problem
Validate Problem Statement
Gather Voice of the Customer & Business
Develop CCR’s & CBR’s
Validate Goal Statement
Validate Business Case
Validate Project Scope
Select and Launch Team
Develop Project Schedule
Complete Define Gate
Appropriately Map Process
Identify Key Input, Process and Output Metrics
Develop Operational Definitions
Develop Data Collection Plan
Validate Measurement System
Collect Baseline Data
Determine Process Performance/Capability
Complete Measure Gate
Identify Potential Root Causes
Reduce List of Potential Root Causes
Confirm Root Cause to Output Relationship
Estimate Impact of Root Causes on Key Outputs
Prioritize Root Causes
Complete Analyze Gate
Develop Potential Solutions
Develop Evaluation Criteria
Select Best Solutions
Develop ‘To-Be’ Process Map(s)
Develop Pilot Plan
Pilot Solution
Develop Full Scale Implementation Plan
Complete Improve Gate
Implement Mistake Proofing
Develop SOP’s, Training Plan and Process Controls
Implement Solution and Ongoing Process Measurements
Identify Project Replication Opportunities
Complete Control Gate
Transition Project to Process Owner
Kaizen, 5S, NVA Analysis,
Generic Pull Systems, Four Step Rapid Setup Method
Identify and Implement Quick Improvements with Kaizen
Tools
Project Charter
Project Selection Tools
PIP Management Process
Value Stream Map
Various Financial Analysis
Effective Meeting Skills
Stakeholder Analysis
Communication Plan
SIPOC Map
High-Level Process Map
Project Management Tools
VOC and Kano Analysis
RACI and Quad Charts
Process Mapping
Process Cycle Efficiency
Little’s Law
Operational Definitions
Data Collection Plan
Statistical Sampling
Measurement System Analysis
TPM
Generic Pull
Setup Reduction
Control Charts
Histograms
Constraint Identification
Process Capability
Value Analysis
Process Constraint ID
Takt Time Analysis
Cause and Effect Analysis
FMEA
Hypothesis Tests
Correlation Analysis
Simple and Multiple Regression
ANOVA
Components of Variation
Conquering Product and Process Complexity
Queuing Theory
Control Charts & SPC
Standard Operating Procedures (SOP’s)
Training Plan
Communication Plan
Implementation Plan
Process Control Plans
Visual Process Control Tools
Project Replication
Project Commissioning
Team Feedback Session
Brainstorming
Replenishment Pull/Kanban
Stocking Strategy
Process Flow Improvement
Process Balancing
Analytical Batch Sizing
Total Productive Maintenance
Design of Experiments (DOE)
Solution Selection Matrix
‘To-Be’ Process Mapping
Poka-Yoke

4. Topics – Week 1 Welcome and Introductions
Introduction to Lean Six Sigma
DMAIC Simulation – Round 1
Introduction to Define Phase
Multi-Generational Project Planning
Project Charters
Project Management
Document and Analyze the Process
Value of Cycle Time
Transactional Cycle Time Simulation
Defining Process Requirements
Define Gate Review
Introduction to Quick Improvement
Quick Improvement – 5S
Quick Improvement – Work Control Systems
Work Control System Exercise
Quick Improvement - Setup Reduction
Introduction to Measure Phase
Introduction to Process Measurement
Determine What to Measure and Data Collection
Variability and Control Charts

5. Topics – Week 2 Measurement Systems Analysis
DMAIC Simulation – Round 2
Process Capability
Measure Gate Review Process
Introduction to Analyze
Basic Tools
Cause and Effect Matrix
Failure Modes & Effects Analysis (FMEA)
Confidence Intervals and Hypothesis Testing
Regression Analysis
Analyze Gate Review Process
Introduction to Improve
Process Flow Improvement Overview
Process Constraint Identification
Process Balancing
Process Flow Improvement
Value Add Time Reduction
Solution Generation and Selection
Pilot the Solution
Improve Gate Review Process
DMAIC Simulation – Round 3
Introduction to Control
Mistake Proofing
Mistake Proofing Exercise
Process Control and Implementation Plans, SOP Documentation
Control Gate Review Process
Project Closeout
Course Closeout