Lean Six Sigma Blackbelt Certification
1. Lean Six Sigma Leadership Seminar (1 Day)
2. Lean & Six Sigma Champion Training (3 Days)
3. Lean & Six Sigma Project Management, OEE, TPM & SMED
(4 Days)
4. Planning for Six Sigma Quality (4 Days)
5. Achieving Continuous Flow (4 Days)
6. Utilizing Supermarket-Pull with Kanbans (4 Days)
7. Achieving Six Sigma Quality (4 Days)
8. Implementing Five S’s for Workplace Organization &
Visual Management for Continual Process Improvement (4 Days)
Total: 28 days
___________________________________________________________________________
Lean / Six Sigma Leadership Seminar (1 Day)
Program Content
This one-day program will help you to understand how your company can use Lean and Six Sigma
technologies to achieve significant improvements in quality, cost and delivery performance. This
seminar offers an overview of the tools, strategies and improvement objectives of Lean / Six
Sigma. Seminar participants will learn how to use Value Stream Mapping and linked scorecards
to plan and deploy Lean / Six Sigma improvement projects. Participants will learn how to take
Lean / Six Sigma from concept to continuous improvement.
Who Should Attend
This program is intended for Senior Management and Operations Managers who have been
selected to play a leadership role in the deployment of Lean Six Sigma in your company. This
program is limited to a maximum of 15 participants.
Prerequisites
None.
Program Goals
To develop understanding of the improvements that can be achieved from adopting an integrated
approach to Lean / Six Sigma and the roles and responsibilities of Company leaders in planning,
organizing and directing Lean / Six Sigma improvement projects. This seminar also develops a
basic level of understanding of the improvement philosophy, strategies and tools of Lean & Six
Sigma. The primary goal of this workshop is to understand the process for identifying and
prioritizing improvement opportunities that can be addressed through Lean / Six Sigma projects.
Program Materials
Each participant will receive a manual of all course materials plus a computer disc of forms, charts,
files and reports needed to plan, organize and improve process performance with Lean / Six
Sigma Technology.
Program Outline
• Introduction to Lean Manufacturing
• Introduction to Six Sigma Quality
• The Philosophy, Strategies and Tools of Lean & Six Sigma
• Lean Demonstration
• The Operational and Financial Benefits of Lean & Six Sigma
• Introduction to Linked Scorecards
• Introduction to Value Stream Mapping
• Drawing Current State Value Stream Maps
• Designing Future State Value Streams
• Leading the Transformation from Current State to Future State
• The Lean / Six Sigma Organization
• Managing Lean / Six Sigma Projects
• Executive Reports and Review
___________________________________________________________________________
Lean & Six Sigma Champion Training (3 Days)
Workshop Content
This three-day workshop develops the knowledge and skills for planning and leading your
company’s Lean & Six Sigma Improvement Process. This workshop introduces Value Stream
Mapping to measure and define the process improvement opportunities. Workshop participants
will analyze and document the current state value stream for one of your existing product families.
They will then create future state value stream maps that identify and quantify the opportunities for
improving process performance through the deployment of Lean & Six Sigma technologies.
Ultimately, the workshop participants will produce project logs and project plans for achieving
those improvements. This workshop also introduces the concept and practice of Linked
Scorecards. Champions will create product, process and project scorecards to link each
improvement project to bottom-line results.
Who Should Attend
This workshop is intended for those responsible for leading and managing the Lean & Six Sigma
improvement projects that will follow. The training is team-based training. Each team should
include the Process Owner (The Champion) and the Lean & Six Sigma Black Belt Candidates (up
to 4 per team). This workshop is limited to three process improvement teams.
Prerequisites
None.
Workshop Materials
Each participant will receive a Lean & Six Sigma Project Planning Manual with all course
materials; and, a CD ROM with files, reporting forms, charts and graphs needed to plan, organize
and deploy Lean & Six Sigma.
Workshop Goals
To develop understanding of the Lean & Six Sigma improvement philosophy, process and tools.
To develop knowledge and skills for creating current and future state value stream maps; and, for
each team to create a current state map, future state map and a Lean & Six Sigma
implementation plan for one of your product families.
Workshop Outline
• Introduction to Lean
• Introduction to Value Stream Mapping
• Drawing Current State Maps
• Measuring the Current Performance – Process & Financial Data Collection
• Analyzing the Current State using the Lean & Six Sigma Planning Process
• Drawing Future State Maps
• Gap Analysis – Future State versus Current State Performance
• Lean Six Sigma Project Planning
• Management Reports & Management Review of Project Plans
___________________________________________________________________________
Lean & Six Sigma Project Management, OEE, TPM & SMED
(4 Days)
Workshop Content
This program develops knowledge and skills for planning, organizing and leading Lean & Six
Sigma Improvement Project Teams. This workshop also offers instruction and practice in
measuring and improving overall equipment effectiveness (OEE). Participants will learn how to
improve OEE by leading project teams to implement a Total Productive Maintenance System
(TPM). Participants will also learn how to reduce setup and changeover times and improve quality
yields through application of SMED (Single Minute Exchange of Dies). This workshop will provide
instruction and guided practice in the application of SMED for streamlining equipment changeover
processes. Participants will also determine the potential cost savings and increased productive
capacity resulting from improved OEE.
Who Should Attend
This workshop is intended for Champions and Lean & Six Sigma Black Belt Candidates
responsible for improving quality and productivity in manufacturing operations. This training is
team-based training. The team should include the Process Champion and up to four Lean & Six
Sigma Black Belt Candidates. There is a limit of 3 teams per session.
Prerequisites
Participants are expected to have completed the Lean Six Sigma Champions Training.
Workshop Materials
Each participant will receive a Manual with all course materials. Each participant will also receive
a CD ROM with programs, charts, graphs, tables and reports necessary to plan, organize and lead
Lean & Six Sigma Improvement Project Teams.
Workshop Goals
To develop knowledge and skills for leading Lean & Six Sigma Project Teams. To develop the
knowledge and ability to measure and manage OEE. To develop the ability to lead project teams
to achieve quick changeovers through application of SMED methodology. To develop knowledge
for leading project teams to plan and implement a system of Total Productive Maintenance.
Workshop Outline
• Introduction to Project Team Leadership
• Defining Team Roles, Responsibilities and Reporting Structures
• Introduction to OEE
• Calculating OEE
• The Six Big Losses That Effect OEE
• Introduction to TPM
• Developing and deploying TPM
• Introduction to SMED for Quick Changeovers
• Developing and Deploying Quick Changeover Methods
• Project Reports
___________________________________________________________________________
Planning for Six Sigma Quality (4 days)
Workshop Content
This program develops knowledge and skills for planning, organizing and leading Lean & Six
Sigma Improvement Project Teams as they plan to achieve Six Sigma Quality. This workshop
offers instruction and practice in measuring and improving process quality levels (measured as
Sigma Levels). Participants will learn how to plan for Six Sigma Quality using The DMAIC (Define,
Measure, Analyze, Improve and Control) Method for quality improvement. This workshop covers
the Define and Measure stages of DMAIC. Participants will learn how to create process maps, to
determine the cost of poor quality for a process; and, to measure and report the process yield,
capability and sigma level.
Who Should Attend
This workshop is intended for Champions and Lean & Six Sigma Black Belt Candidates
responsible for improving quality and productivity in manufacturing operations. This training is
team-based training. The team should include the Process Champion and up to four Lean & Six
Sigma Black Belt Candidates. There is a limit of 3 teams per session.
Prerequisites
Participants are expected to have completed the Lean & Six Sigma Champions Training and all
previous Black Belt Workshops.
Workshop Materials
Each participant will receive a Manual with all course materials. Each participant will also receive
a CD ROM with programs, charts, graphs, tables and reports necessary to plan, organize and lead
Lean & Six Sigma Improvement Project Teams.
Workshop Goals
To develop knowledge and skills for leading Six Sigma Quality Improvement Teams. For the Lean
& Six Sigma teams to complete the Define and Measure stages of DMAIC quality improvement
process. To be able to identify and quantify the quality improvement opportunities in your process.
To be able to perform process capability studies and determine Sigma Levels for any process
measure.
Workshop Outline
• Introduction to Six Sigma Quality
• Introduction to DMAIC Process and Tools
• Introduction to Cost of Poor Quality
• Process Mapping
• Process Failure Mode & Effects Analysis (PFMEA)
• Process Capability Analysis
• Sigma, CP, CPk and DPMO
• Process Control Plans
• Statistical Process Control Charts
• Management Review and Reporting Process
___________________________________________________________________________
Achieving Continuous Flow (4 Days)
Workshop Content
This four-day workshop develops knowledge and skills for implementing continuous flow in
manufacturing and assembly processes. Participants will learn: how to conduct work element
analysis, how to calculate takt times, how to create operator balance charts, how to evaluate and
improve equipment layout and material presentation; and, how to plan and implement standard
work methods to reduce the labor, material and facilities costs in manufacturing and assembly
operations.
Who Should Attend
This workshop is intended for Lean & Six Sigma Black Belts responsible for planning, organizing
and managing continuous improvement of manufacturing and assembly processes. This training is
team-based training. Each team should include the Champion plus up to four Lean & Six Sigma
Black Belt Candidates. A maximum of three teams is allowed per session.
Prerequisites
Participants must have completed Champion Training and all previous Lean & Six Sigma Black
Belt Workshops.
Workshop Materials
Each participant will receive a Manual with all course materials included. They will also receive a
CD ROM of charts, graphs, reports, files and forms necessary to plan, organize and deploy Lean &
Six Sigma.
Workshop Goals
This workshop is intended to develop knowledge of the philosophy, process and tools of
continuous flow processing. This workshop will also provide participants with the opportunity to
practice the application of continuous flow processing in a live manufacturing or assembly
process. This workshop will also help participants to identify and quantify the cost savings from
continuous flow processing projects.
Workshop Outline
• Introduction to Continuous Flow Processing
• Conducting the Process Analysis – Current State Performance Data
• Constructing Operator Balance Charts
• Analyzing the Current Layout and Material Flow
• Performing Paper Kaizens
• Considering the Role of Automation
• Designing the Future State Layout and Material Flow
• Determining the Cost Savings from Continuous Flow Processing
• Planning & Deploying the Future State Cell Design
• Developing Standard Work Methods and Charts
• Management Reports
___________________________________________________________________________
Utilizing Supermarket-Pull with Kanbans (4 Days)
Workshop Content
This four-day workshop develops knowledge and skills for developing pull-scheduling systems to
be used where continuous flow is not yet possible. Participants will learn how to determine
appropriate levels of inventory needed to maintain production schedules with minimum waste.
Participants will learn how to develop and deploy kanbans for real-time shop floor production
scheduling and inventory management. Participants will learn how to determine the cost savings
from supermarket-pull scheduling.
Who Should Attend
This workshop is intended for Lean & Six Sigma Champions and Black Belt Candidates
responsible for planning, organizing and completing Lean & Six Sigma Projects. This training is
team-based training. Each team should include the Lean & Six Sigma Champion and up to four
Lean & Six Sigma Black Belt Candidates. Maximum of 3 teams per session allowed.
Prerequisites
Participants must have completed Champion Training and all previous Lean & Six Sigma
Workshops prior to enrolling in this program.
Workshop Materials
Each participant will receive a Supermarket-Pull Scheduling Manual that contains all course
materials. Each participant will also receive a CD ROM with files, reports, forms and charts used
to plan, organize and deploy Lean & Six Sigma.
Workshop Goals
This workshop is intended to develop understanding of supermarkets, pull scheduling and
kanbans. To develop knowledge and skills for deploying supermarkets & kanbans to control
inventory levels and schedule the production and delivery of raw materials, work-in-process and
finished goods inventories. To practice the deployment of supermarket pull systems using kanbans
in a live manufacturing, assembly or purchasing process. To identify and quantify the cost savings
from the improved inventory control and production scheduling performance resulting from the use
of pull scheduling.
Workshop Outline
• Introduction to Pull Systems
• Introduction to Supermarkets
• Introduction to Kanbans
• Introduction to Heijunka (leveling)
• Determining Appropriate Inventory Levels
• Designing Supermarkets
• Creating Kanbans for Production Scheduling & Inventory Control
• Determining Cost Savings from the Supermarket Pull System
• Management and Continuous Improvement of the Supermarket Pull System
• Management Reports & Management Review
___________________________________________________________________________
Achieving Six Sigma Quality (4 Days)
Workshop Content
This four-day workshop develops the knowledge and skills for analyzing, improving and controlling
processes to achieve Six Sigma Quality. Participants will learn how to use control charts, multi-
vari charts, hypothesis testing and DOE to analyze process variation and to identify the process
improvements necessary to achieve six sigma quality. Participants will learn how to plan and
organize resources to implement and sustain six sigma quality improvements.
Who Should Attend
This workshop is intended for Champions and Black Belt Candidates responsible for planning and
completing Lean & Six Sigma improvement projects.
Prerequisites
Participants must have completed Champion Training and all previous Lean & Six Sigma
Workshops prior to enrolling in this workshop.
Workshop Materials
Each workshop participant will receive a Manual with all course materials. Each participant will
also receive a CD ROM with all necessary files, reports, forms, charts, graphs and tables
necessary to plan, organize and lead Lean & Six Sigma Project Teams.
Workshop Goals
This workshop is intended to develop understanding and ability to apply the process and tools
used to complete the Analyze and Improve Stages of DMAIC. Participants will learn how to:
perform SPC Chart Analysis, Complete the Statistical Problem Solving Process and to design,
conduct and analyze experiments to identify process improvement targets and define improvement
goals necessary to achieve six sigma process quality.
Workshop Outline
• Review of DMAIC
• Variation Analysis
• Statistical Problem Solving
• Hypothesis Testing
• Design of Experiments
• Improvement Project Planning
• Preparing and Presenting Management Reports
• 2-hour Greenbelt Exam
2-hour Greenbelt Exam on Day 4
___________________________________________________________________________
Implementing Five S’s for Workplace Organization & Visual
Management for Continual Process Improvement (4 Days)
Workshop Content
This four-day workshop develops the knowledge and skills for planning, organizing and
implementing the Five S Method for Workplace Organization. Workshop participants will also learn
how the Five S process fits into a total system of Visual Management. Workshop participants will
receive instruction and guided practice in planning and deploying visual management systems for
the continual improvement of process quality, productivity, housekeeping, safety and employee
development. Participants will learn how to create standards for each type of performance and to
use the concept and practice of Visual Controls to integrate those standards into daily practice.
Who Should Attend
This workshop is intended for Champions and Black Belt Candidates responsible for
implementing and managing Lean & Six Sigma improvement projects.
Prerequisites
This is the final workshop in the Lean & Six Sigma Training System. Participants must have
completed Champion Training and all previous Lean & Six Sigma Workshops prior to enrolling in
this program.
Workshop Materials
Each workshop participant will receive a Manual with all course materials. Each participant will
also receive a CD ROM with all necessary files, reports, forms, charts, graphs and tables
necessary to plan, organize and lead Lean Six Sigma Project Teams.
Workshop Goals
This workshop develops understanding of the philosophy and process for achieving workplace
organization through the Five S Method. Participants will conduct a Five S Campaign to clean and
organize one or more locations in your plant/office operations. Participants will also utilize Visual
Management Methods to Control process performance in order to “hold the gains” achieved.
Workshop Outline
• Introduction to the Five S Method
• Sort - identify and sort items by frequency of use
• Store – prepare and label storage locations for all items
• Shine – conduct a campaign to repair, clean and shine the work area
• Sustain – implement regular 5 S audits to sustain the improvements
• Spread – apply the lessons learned to other plant/office areas
• Introduction to Visual Management
• How to write Performance Standards
• Making Performance Standards Visual
• Preparing and presenting Management Reports
1. Lean Six Sigma Leadership Seminar (1 Day)
2. Lean & Six Sigma Champion Training (3 Days)
3. Lean & Six Sigma Project Management, OEE, TPM & SMED
(4 Days)
4. Planning for Six Sigma Quality (4 Days)
5. Achieving Continuous Flow (4 Days)
6. Utilizing Supermarket-Pull with Kanbans (4 Days)
7. Achieving Six Sigma Quality (4 Days)
8. Implementing Five S’s for Workplace Organization &
Visual Management for Continual Process Improvement (4 Days)
Total: 28 days
___________________________________________________________________________
Lean / Six Sigma Leadership Seminar (1 Day)
Program Content
This one-day program will help you to understand how your company can use Lean and Six Sigma
technologies to achieve significant improvements in quality, cost and delivery performance. This
seminar offers an overview of the tools, strategies and improvement objectives of Lean / Six
Sigma. Seminar participants will learn how to use Value Stream Mapping and linked scorecards
to plan and deploy Lean / Six Sigma improvement projects. Participants will learn how to take
Lean / Six Sigma from concept to continuous improvement.
Who Should Attend
This program is intended for Senior Management and Operations Managers who have been
selected to play a leadership role in the deployment of Lean Six Sigma in your company. This
program is limited to a maximum of 15 participants.
Prerequisites
None.
Program Goals
To develop understanding of the improvements that can be achieved from adopting an integrated
approach to Lean / Six Sigma and the roles and responsibilities of Company leaders in planning,
organizing and directing Lean / Six Sigma improvement projects. This seminar also develops a
basic level of understanding of the improvement philosophy, strategies and tools of Lean & Six
Sigma. The primary goal of this workshop is to understand the process for identifying and
prioritizing improvement opportunities that can be addressed through Lean / Six Sigma projects.
Program Materials
Each participant will receive a manual of all course materials plus a computer disc of forms, charts,
files and reports needed to plan, organize and improve process performance with Lean / Six
Sigma Technology.
Program Outline
• Introduction to Lean Manufacturing
• Introduction to Six Sigma Quality
• The Philosophy, Strategies and Tools of Lean & Six Sigma
• Lean Demonstration
• The Operational and Financial Benefits of Lean & Six Sigma
• Introduction to Linked Scorecards
• Introduction to Value Stream Mapping
• Drawing Current State Value Stream Maps
• Designing Future State Value Streams
• Leading the Transformation from Current State to Future State
• The Lean / Six Sigma Organization
• Managing Lean / Six Sigma Projects
• Executive Reports and Review
___________________________________________________________________________
Lean & Six Sigma Champion Training (3 Days)
Workshop Content
This three-day workshop develops the knowledge and skills for planning and leading your
company’s Lean & Six Sigma Improvement Process. This workshop introduces Value Stream
Mapping to measure and define the process improvement opportunities. Workshop participants
will analyze and document the current state value stream for one of your existing product families.
They will then create future state value stream maps that identify and quantify the opportunities for
improving process performance through the deployment of Lean & Six Sigma technologies.
Ultimately, the workshop participants will produce project logs and project plans for achieving
those improvements. This workshop also introduces the concept and practice of Linked
Scorecards. Champions will create product, process and project scorecards to link each
improvement project to bottom-line results.
Who Should Attend
This workshop is intended for those responsible for leading and managing the Lean & Six Sigma
improvement projects that will follow. The training is team-based training. Each team should
include the Process Owner (The Champion) and the Lean & Six Sigma Black Belt Candidates (up
to 4 per team). This workshop is limited to three process improvement teams.
Prerequisites
None.
Workshop Materials
Each participant will receive a Lean & Six Sigma Project Planning Manual with all course
materials; and, a CD ROM with files, reporting forms, charts and graphs needed to plan, organize
and deploy Lean & Six Sigma.
Workshop Goals
To develop understanding of the Lean & Six Sigma improvement philosophy, process and tools.
To develop knowledge and skills for creating current and future state value stream maps; and, for
each team to create a current state map, future state map and a Lean & Six Sigma
implementation plan for one of your product families.
Workshop Outline
• Introduction to Lean
• Introduction to Value Stream Mapping
• Drawing Current State Maps
• Measuring the Current Performance – Process & Financial Data Collection
• Analyzing the Current State using the Lean & Six Sigma Planning Process
• Drawing Future State Maps
• Gap Analysis – Future State versus Current State Performance
• Lean Six Sigma Project Planning
• Management Reports & Management Review of Project Plans
___________________________________________________________________________
Lean & Six Sigma Project Management, OEE, TPM & SMED
(4 Days)
Workshop Content
This program develops knowledge and skills for planning, organizing and leading Lean & Six
Sigma Improvement Project Teams. This workshop also offers instruction and practice in
measuring and improving overall equipment effectiveness (OEE). Participants will learn how to
improve OEE by leading project teams to implement a Total Productive Maintenance System
(TPM). Participants will also learn how to reduce setup and changeover times and improve quality
yields through application of SMED (Single Minute Exchange of Dies). This workshop will provide
instruction and guided practice in the application of SMED for streamlining equipment changeover
processes. Participants will also determine the potential cost savings and increased productive
capacity resulting from improved OEE.
Who Should Attend
This workshop is intended for Champions and Lean & Six Sigma Black Belt Candidates
responsible for improving quality and productivity in manufacturing operations. This training is
team-based training. The team should include the Process Champion and up to four Lean & Six
Sigma Black Belt Candidates. There is a limit of 3 teams per session.
Prerequisites
Participants are expected to have completed the Lean Six Sigma Champions Training.
Workshop Materials
Each participant will receive a Manual with all course materials. Each participant will also receive
a CD ROM with programs, charts, graphs, tables and reports necessary to plan, organize and lead
Lean & Six Sigma Improvement Project Teams.
Workshop Goals
To develop knowledge and skills for leading Lean & Six Sigma Project Teams. To develop the
knowledge and ability to measure and manage OEE. To develop the ability to lead project teams
to achieve quick changeovers through application of SMED methodology. To develop knowledge
for leading project teams to plan and implement a system of Total Productive Maintenance.
Workshop Outline
• Introduction to Project Team Leadership
• Defining Team Roles, Responsibilities and Reporting Structures
• Introduction to OEE
• Calculating OEE
• The Six Big Losses That Effect OEE
• Introduction to TPM
• Developing and deploying TPM
• Introduction to SMED for Quick Changeovers
• Developing and Deploying Quick Changeover Methods
• Project Reports
___________________________________________________________________________
Planning for Six Sigma Quality (4 days)
Workshop Content
This program develops knowledge and skills for planning, organizing and leading Lean & Six
Sigma Improvement Project Teams as they plan to achieve Six Sigma Quality. This workshop
offers instruction and practice in measuring and improving process quality levels (measured as
Sigma Levels). Participants will learn how to plan for Six Sigma Quality using The DMAIC (Define,
Measure, Analyze, Improve and Control) Method for quality improvement. This workshop covers
the Define and Measure stages of DMAIC. Participants will learn how to create process maps, to
determine the cost of poor quality for a process; and, to measure and report the process yield,
capability and sigma level.
Who Should Attend
This workshop is intended for Champions and Lean & Six Sigma Black Belt Candidates
responsible for improving quality and productivity in manufacturing operations. This training is
team-based training. The team should include the Process Champion and up to four Lean & Six
Sigma Black Belt Candidates. There is a limit of 3 teams per session.
Prerequisites
Participants are expected to have completed the Lean & Six Sigma Champions Training and all
previous Black Belt Workshops.
Workshop Materials
Each participant will receive a Manual with all course materials. Each participant will also receive
a CD ROM with programs, charts, graphs, tables and reports necessary to plan, organize and lead
Lean & Six Sigma Improvement Project Teams.
Workshop Goals
To develop knowledge and skills for leading Six Sigma Quality Improvement Teams. For the Lean
& Six Sigma teams to complete the Define and Measure stages of DMAIC quality improvement
process. To be able to identify and quantify the quality improvement opportunities in your process.
To be able to perform process capability studies and determine Sigma Levels for any process
measure.
Workshop Outline
• Introduction to Six Sigma Quality
• Introduction to DMAIC Process and Tools
• Introduction to Cost of Poor Quality
• Process Mapping
• Process Failure Mode & Effects Analysis (PFMEA)
• Process Capability Analysis
• Sigma, CP, CPk and DPMO
• Process Control Plans
• Statistical Process Control Charts
• Management Review and Reporting Process
___________________________________________________________________________
Achieving Continuous Flow (4 Days)
Workshop Content
This four-day workshop develops knowledge and skills for implementing continuous flow in
manufacturing and assembly processes. Participants will learn: how to conduct work element
analysis, how to calculate takt times, how to create operator balance charts, how to evaluate and
improve equipment layout and material presentation; and, how to plan and implement standard
work methods to reduce the labor, material and facilities costs in manufacturing and assembly
operations.
Who Should Attend
This workshop is intended for Lean & Six Sigma Black Belts responsible for planning, organizing
and managing continuous improvement of manufacturing and assembly processes. This training is
team-based training. Each team should include the Champion plus up to four Lean & Six Sigma
Black Belt Candidates. A maximum of three teams is allowed per session.
Prerequisites
Participants must have completed Champion Training and all previous Lean & Six Sigma Black
Belt Workshops.
Workshop Materials
Each participant will receive a Manual with all course materials included. They will also receive a
CD ROM of charts, graphs, reports, files and forms necessary to plan, organize and deploy Lean &
Six Sigma.
Workshop Goals
This workshop is intended to develop knowledge of the philosophy, process and tools of
continuous flow processing. This workshop will also provide participants with the opportunity to
practice the application of continuous flow processing in a live manufacturing or assembly
process. This workshop will also help participants to identify and quantify the cost savings from
continuous flow processing projects.
Workshop Outline
• Introduction to Continuous Flow Processing
• Conducting the Process Analysis – Current State Performance Data
• Constructing Operator Balance Charts
• Analyzing the Current Layout and Material Flow
• Performing Paper Kaizens
• Considering the Role of Automation
• Designing the Future State Layout and Material Flow
• Determining the Cost Savings from Continuous Flow Processing
• Planning & Deploying the Future State Cell Design
• Developing Standard Work Methods and Charts
• Management Reports
___________________________________________________________________________
Utilizing Supermarket-Pull with Kanbans (4 Days)
Workshop Content
This four-day workshop develops knowledge and skills for developing pull-scheduling systems to
be used where continuous flow is not yet possible. Participants will learn how to determine
appropriate levels of inventory needed to maintain production schedules with minimum waste.
Participants will learn how to develop and deploy kanbans for real-time shop floor production
scheduling and inventory management. Participants will learn how to determine the cost savings
from supermarket-pull scheduling.
Who Should Attend
This workshop is intended for Lean & Six Sigma Champions and Black Belt Candidates
responsible for planning, organizing and completing Lean & Six Sigma Projects. This training is
team-based training. Each team should include the Lean & Six Sigma Champion and up to four
Lean & Six Sigma Black Belt Candidates. Maximum of 3 teams per session allowed.
Prerequisites
Participants must have completed Champion Training and all previous Lean & Six Sigma
Workshops prior to enrolling in this program.
Workshop Materials
Each participant will receive a Supermarket-Pull Scheduling Manual that contains all course
materials. Each participant will also receive a CD ROM with files, reports, forms and charts used
to plan, organize and deploy Lean & Six Sigma.
Workshop Goals
This workshop is intended to develop understanding of supermarkets, pull scheduling and
kanbans. To develop knowledge and skills for deploying supermarkets & kanbans to control
inventory levels and schedule the production and delivery of raw materials, work-in-process and
finished goods inventories. To practice the deployment of supermarket pull systems using kanbans
in a live manufacturing, assembly or purchasing process. To identify and quantify the cost savings
from the improved inventory control and production scheduling performance resulting from the use
of pull scheduling.
Workshop Outline
• Introduction to Pull Systems
• Introduction to Supermarkets
• Introduction to Kanbans
• Introduction to Heijunka (leveling)
• Determining Appropriate Inventory Levels
• Designing Supermarkets
• Creating Kanbans for Production Scheduling & Inventory Control
• Determining Cost Savings from the Supermarket Pull System
• Management and Continuous Improvement of the Supermarket Pull System
• Management Reports & Management Review
___________________________________________________________________________
Achieving Six Sigma Quality (4 Days)
Workshop Content
This four-day workshop develops the knowledge and skills for analyzing, improving and controlling
processes to achieve Six Sigma Quality. Participants will learn how to use control charts, multi-
vari charts, hypothesis testing and DOE to analyze process variation and to identify the process
improvements necessary to achieve six sigma quality. Participants will learn how to plan and
organize resources to implement and sustain six sigma quality improvements.
Who Should Attend
This workshop is intended for Champions and Black Belt Candidates responsible for planning and
completing Lean & Six Sigma improvement projects.
Prerequisites
Participants must have completed Champion Training and all previous Lean & Six Sigma
Workshops prior to enrolling in this workshop.
Workshop Materials
Each workshop participant will receive a Manual with all course materials. Each participant will
also receive a CD ROM with all necessary files, reports, forms, charts, graphs and tables
necessary to plan, organize and lead Lean & Six Sigma Project Teams.
Workshop Goals
This workshop is intended to develop understanding and ability to apply the process and tools
used to complete the Analyze and Improve Stages of DMAIC. Participants will learn how to:
perform SPC Chart Analysis, Complete the Statistical Problem Solving Process and to design,
conduct and analyze experiments to identify process improvement targets and define improvement
goals necessary to achieve six sigma process quality.
Workshop Outline
• Review of DMAIC
• Variation Analysis
• Statistical Problem Solving
• Hypothesis Testing
• Design of Experiments
• Improvement Project Planning
• Preparing and Presenting Management Reports
• 2-hour Greenbelt Exam
2-hour Greenbelt Exam on Day 4
___________________________________________________________________________
Implementing Five S’s for Workplace Organization & Visual
Management for Continual Process Improvement (4 Days)
Workshop Content
This four-day workshop develops the knowledge and skills for planning, organizing and
implementing the Five S Method for Workplace Organization. Workshop participants will also learn
how the Five S process fits into a total system of Visual Management. Workshop participants will
receive instruction and guided practice in planning and deploying visual management systems for
the continual improvement of process quality, productivity, housekeeping, safety and employee
development. Participants will learn how to create standards for each type of performance and to
use the concept and practice of Visual Controls to integrate those standards into daily practice.
Who Should Attend
This workshop is intended for Champions and Black Belt Candidates responsible for
implementing and managing Lean & Six Sigma improvement projects.
Prerequisites
This is the final workshop in the Lean & Six Sigma Training System. Participants must have
completed Champion Training and all previous Lean & Six Sigma Workshops prior to enrolling in
this program.
Workshop Materials
Each workshop participant will receive a Manual with all course materials. Each participant will
also receive a CD ROM with all necessary files, reports, forms, charts, graphs and tables
necessary to plan, organize and lead Lean Six Sigma Project Teams.
Workshop Goals
This workshop develops understanding of the philosophy and process for achieving workplace
organization through the Five S Method. Participants will conduct a Five S Campaign to clean and
organize one or more locations in your plant/office operations. Participants will also utilize Visual
Management Methods to Control process performance in order to “hold the gains” achieved.
Workshop Outline
• Introduction to the Five S Method
• Sort - identify and sort items by frequency of use
• Store – prepare and label storage locations for all items
• Shine – conduct a campaign to repair, clean and shine the work area
• Sustain – implement regular 5 S audits to sustain the improvements
• Spread – apply the lessons learned to other plant/office areas
• Introduction to Visual Management
• How to write Performance Standards
• Making Performance Standards Visual
• Preparing and presenting Management Reports
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