Lean Six Sigma Green Belt

Operational Auditing and Quality Assurance October 25, 2025
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Introduction

The Lean Six Sigma Green Belt certification is designed for professionals who will lead medium-complexity process improvement projects and act as subject matter experts within project teams. This course provides a deep, practical application of the DMAIC (Define, Measure, Analyze, Improve, Control) methodology, focusing on data analysis, statistical methods, and effective team leadership. Green Belts are equipped to solve significant business problems by identifying root causes of variation and waste, designing robust solutions, and ensuring sustainable control, thereby driving measurable improvements in quality, cost, and delivery.

Objectives

Upon completion of this course, participants will be able to:

  • Lead and manage Lean Six Sigma projects from initiation to closure.
  • Define, scope, and create an effective project charter and team structure.
  • Select appropriate statistical and graphical tools to analyze process data.
  • Apply inferential statistics to validate root causes and test hypotheses.
  • Design and implement effective, sustainable solutions to process problems.
  • Utilize Lean tools (e.g., VSM, Kaizen) to eliminate waste and non-value-added activities.
  • Develop and deploy robust control plans to maintain process gains.
  • Present project results and recommendations clearly to stakeholders and management.

Target Audience

  • Project Managers, Process Engineers, and Team Leaders.
  • Quality Assurance and Quality Control personnel.
  • Managers and Supervisors responsible for operational performance.
  • Analysts seeking to enhance their data-driven problem-solving skills.
  • Individuals committed to leading significant process improvement initiatives.
  • Consultants and trainers specializing in quality and efficiency.

Methodology

  • In-depth Case Studies (e.g., manufacturing/service process improvement).
  • Statistical Software Exercises (e.g., Minitab or similar for data analysis).
  • Group Simulation: Conducting a Value Stream Mapping (VSM) exercise.
  • Role-Playing: Project Charter review and stakeholder management.
  • Practical Application: Design and implementation of a Control Plan.

Personal Impact

  • Achieve the internationally recognized Lean Six Sigma Green Belt certification.
  • Develop expertise in using data and statistical analysis for complex problem-solving.
  • Gain the competence to lead and manage improvement projects effectively.
  • Improve decision-making by basing solutions on verified data and root causes.
  • Enhance leadership and change management skills within a team context.
  • Significant career advancement opportunities in operations and quality.

Organizational Impact

  • Successful completion of medium-to-high complexity, high-impact improvement projects.
  • Measurable reduction in operational costs, defects, and process variation.
  • Development of internal expertise in data-driven decision-making and problem-solving.
  • Improved process efficiency, cycle time, and customer satisfaction.
  • A culture of continuous improvement supported by trained project leaders.
  • Stronger bottom-line results through effective waste elimination.

Course Outline

Unit 1: Define Phase - Project Scoping and Foundation

Section 1.1: Project Management
  • Creating and validating a comprehensive project charter.
  • Identifying and engaging process stakeholders (VoC and CTQ tree).
  • Advanced process mapping (SIPOC, detailed swimlane diagrams).
  • Understanding the financial benefits and baseline of the project.
Section 1.2: Team Dynamics and Lean
  • Team leadership, communication, and management skills.
  • In-depth analysis of the eight wastes (Muda) and their impact.
  • Introduction to Kaizen events and rapid improvement techniques.
  • Creating a detailed Value Stream Map (VSM) to identify bottlenecks.

Unit 2: Measure Phase - Data Collection and Baseline

Section 2.1: Statistical Fundamentals
  • Data types, sources, and effective data collection planning.
  • Understanding and calculating Process Capability (Cp, Cpk, Pp, Ppk).
  • Graphical analysis tools (Pareto, Histogram, Box Plot, Run Chart).
  • Introduction to Measurement System Analysis (MSA) and Gage R&R.

Unit 3: Analyze Phase - Root Cause Analysis (RCA)

Section 3.1: Identifying Critical Inputs
  • Hypothesis testing fundamentals (e.g., t-tests, ANOVA introduction).
  • Advanced Root Cause Analysis (RCA) tools (Ishikawa, detailed cause-and-effect).
  • Process modeling and statistical screening of potential critical X's.
  • Segmentation, stratification, and analysis of process data.

Unit 4: Improve Phase - Solution Design and Implementation

Section 4.1: Optimizing the Process
  • Generating, evaluating, and selecting robust solutions (Pugh Matrix).
  • Introduction to Design of Experiments (DOE) concepts.
  • Implementing Lean tools like cellular manufacturing and Poka-Yoke (Error-Proofing).
  • Conducting pilot studies and verifying solution effectiveness.

Unit 5: Control Phase - Sustaining the Gains

Section 5.1: Process Control and Closure
  • Developing a comprehensive Control Plan.
  • Statistical Process Control (SPC) and selecting the right control charts.
  • Standardizing work and training for long-term control.
  • Finalizing financial validation and formal project closure.

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