Lean sigma manufacturing greenbelt

This programme is designed to provide delegates with an integrated approach for improving the flow, capability and consistency of manufacturing processes, thereby reducing waste, increasing customer satisfaction and improving business performance. The robust ''DMAIC'' approach provides a common structure for improvement, within which a wide range of techniques can be applied. Improvement projects undertaken by delegates are a key feature of this Green Belt programme, enabling them to ''learn by doing'', and providing an immediate return for their companies.
PROGRAMME OBJECTIVES

• To develop a clear understanding of value, waste & process variability
  
• To ensure that the essential foundations are in place for successful Lean Sigma deployment
  
• To provide a truly integrated, structured improvement methodology
  
• To introduce a range of techniques for improving process flow and efficiency, & reducing variability within manufacturing processes
  
• To ensure the sustainability of process improvements To achieve significant improvements during the training programme
  

PROGRAMME CONTENT
BLOCK 1
Day 1
Day 2
Day 3
Day 4
Introduction to Lean Sigma

• Programme introduction
  
• Objectives & origins of Lean Sigma
  
• The value of an integrated approach
  
• Understanding value, waste & process variability
  
• Developing a Lean Sigma improvement strategy & implementation plan
  
• Policy deployment & performance measurement
  

Lean Sigma Foundations

• Building a sustainable CI improvement culture
  
• 5S workplace organisation
  
• Creating a visual workplace
  
• Daily management
  
• Structured approaches to improvement
  
• Sources & types of manufacturing Problems: flow & consistency
  
• The DMAIC approach - a single structure
  
• Lean Sigma roadmap & toolkit
  

DMAIC Structured Improvement Methodology

• DMAIC improvement exercise
  
• Defining & scoping the problem
  
• Mapping, measuring & assessing processes
  
• Analysing the facts & finding the root causes
  
• Improving the process with creative solutions
  
• Implementing, sustaining & replicating the gains
  
• Reviewing performance
  

Initiating Lean Sigma Projects

• Project identification, scoping & selection
  
• Project planning & getting started
  
• Project reviews & support
  
• Measuring project success
  
• Action planning
  
• Block 1 assessment, summary & review
  

BLOCK 2
Day 5
Day 6
Day 7
Day 8
Measuring Process
Variability

• Using the DMAIC process to improve process variability
  
• Basic statistics
  
• Introduction to Minitab
  
• Measurement System Analysis (R&R Studies)
  
• Graphical analysis
  
• Capability analysis
  

Analysing Process Variability

• Statistical analysis techniques
  
• Introduction to hypothesis testing
  
• Introduction to regression analysis
  
• Identifying key process input variables using Design of Experiments (DOE)
  

Improving & Controlling Process Variability

• Improving process performance using DOE
  
• Introduction to screening techniques & Taguchi experiments
  
• Controlling process variability using SPC control charts
  

Leadership & Change Management

• Managing organisational change
  
• The dynamics & process of change
  
• Building commitment to change
  
• Leading, building & coaching effective improvement teams
  
• Action planning
  
• Block 2 assessment, summary & review
  

BLOCK3
Day 9
Day 10
Day 11
Day 12
Value Stream Mapping & Improving Process Flow

• Using the DMAIC process to improve process flow
  
• Introduction to Value Stream Mapping
  
• Drawing & evaluating the current state map
  
• Lean techniques for improving process flow
  
• Creating the future state map
  
• Developing the improvement plan
  

Improving Overall Equipment Effectiveness

• Measuring & improving Overall Equipment Effectiveness
  
• Total Productive Maintenance (TPM)
  
• Implementing autonomous maintenance
  
• Rapid Changeover Techniques (SMED)
  
• 4-Step changeover reduction
  
• Changeover improvement activity
  

Mistake Proofing & Cellular Manufacturing

• Achieving zero defects with Mistake Proofing (Poka Yoke)
  
• Mistake Proofing in manufacture, design & the office
  
• Factory layout & cellular manufacturing
  
• Introduction to lean supply chains
  
• Factory simulation & improvement activity
  

Project Closure & Sustainability

• Project closure & sign-off
  
• Building sustainability (process audits, ongoing performance reviews etc)
  
• Green Belt certification requirements: final project reports & presentations
  
• Action planning
  
• Block 3 assessment, summary & review
  

BLOCK4
Day 13
Day 14
On-Site Project Review

• Project review at delegate''s workplace
  
• Coaching & support for final report & presentation
  

Certification Event

• Final project presentations
  
• Programme summary & review
  
• Award of certificates
  

ACCREDITATION
This programme includes an accreditation process that includes a project, multi-choice examination and project presentation.