Six Sigma Green Belt

Six Sigma Green Belt Outline

Module 1: Introduction to Lean 6 Sigma 

• What is Lean 6 Sigma? 

• Two Parts of Lean 6 Sigma 

• Focus of Lean 

• Lean Temple 

• Focus of Six Sigma 

• Making Customers Happy 

• How They Complement Each Other? 

• Key Principles of Lean 6 Sigma 

• Lean 6 Sigma Belts 

• TKA Lean 6 Sigma Belt Structure 

• Training Roadmap and Role of the Yellow Belt 

• L6S Support Network 

• Processes 

• Different Ways of Looking at Process Improvement 

• What is a Process? 

• Process Concepts 

• Types of Process 

• Comparing Process Types 

• Customers, Value, and Waste 

• What are Customers? 

• Who Wants the Outputs? 

• Tension Between the VOB and VOC 

• What Do We Mean by Value? 

• Path to Value 

• Dealing with Values 

• Muda (Waste) 

• Wastes (Muda) of Lean 

• Types of Demand 

• Case Study Exercise 

• Key Metrics 
   

Module 2: DMAIC Cycle 

• What is DMAIC? 

• Define 

• Common Tools for Define Phase 

• Gemba Tools 

• Process Stapling 

• Measure 

• Common Tools for Measure Phase 

• Spaghetti (Movement/Transportation) Diagrams 

• Analyse 

• Common Tools for Analyse Phase 

• Improve 

• Common Tools for Improve Phase 

• Control 

• Common Tools for Control Phase 
   

Module 3: Yellow Belt Tools and Techniques 

• Lean Triad 

• 5s 

• Poka Yoke 

• SMED 

• Voice of the Customer (and CTQ’s) 

• Customer Chains 

• Steps of VOC 

• Affinity Diagrams 

• Kano Diagrams 

• CTQs and Requirements 

• SIPOC 

• What is a SIPOC? 

• CSandF Web Fulfilment SIPOC 

• Creating a SIPOC 

• Top Tips – SIPOC 

• Value Stream Analysis 

• Value Stream Terminology 

• Process Maps 

• Aim of Value Stream Mapping 

• Swim Lanes and Typical Process Map Contents 

• Value Stream Maps 

• Headache Tablets: Value Stream Mapping 

• Heijunka 

• Heijunka in a Nutshell 

• Single Piece Flow 

• Pull 

• Kanban 

• Three-Bin System 

• Andon 

• Variation and SPC 

• Statistical Process Control (SPC) 

• Two Types of Process Variation 

• Red Bead Experiment 

• Standard Deviation (SD) and Understanding Control Charts 

• Defects and Process Capability 

• Conversion Table 

• Process Capability 

• Identifying Process Efficiency 

• Key DPMO Terms 

• Identifying the Root Cause(s) 

• 5 Whys 

• Fishbone Diagram 

• Solving Problems 

• Problem Solving Framework 

• Prioritisation Tools 

• Tools and Techniques to Generate Needed Solutions 

• Introduction to Kaizen 

• Kaizen in a Nutshell 

• Kaizen in a Business Setting 

• Lean Teams 

• Introduction to Lean Team 

• Managing Progress and Demonstrating Control 
   

Module 4: Improvement Methodologies 

• DMAIC 

• 3Cs 

• 8Ds 

• Plan Do Check Act 

• Kaizen 

• Design for Six Sigma (DFSS) 
   

Module 5: SPC Basics 

• Terminology 

• Data Types 

• Normal Distribution and Standard Deviation 

• Process Capability 
   

Module 6: Lean Management and Cell Theory 

• Role of the Lean Manager 

• Work Cells 

• High Performing Teams (HPTs) 

• Rapid Action Teams (RATs) 

• Visual Management 

• Bruce Tuckman’s Group Development Model 

• Emotional Cycle of Change (ECOC) 

• Personality Styles 

• Dealing with Resistance 
   

Module 7: Risk Management 

• Green Belt Risk Management 

• FMEA: Failure Mode and Effects Analysis 
   

Module 8: DMAIC for Green Belts 

• Define Phase 

• Measure Phase 
   

Module 9: SPC Tools and Techniques 

• Frequency Distribution Tables 

• Bar Charts and Histograms 

• Pareto Charts 

• Box and Whisker Plots 

• Normal Distribution and Control Charts 

• Calculating Process Efficiency 

• Scatter Diagrams and Regression 
   

Module 10: Analyse Phase 

• Analyse 

• Process Maps 

• Process Map Levels 

• On the Ground Instructions (OTGIs) 

• Value Stream Maps 

• What is a Value Stream? 

• Creating the “As Is” VSM 

• Investigating and Understanding the Process 

• Headache Tablets: Value Stream Mapping 

• Creating a VSM: Process Borders Definition 

• Using Swim Lane Diagrams to Identify Logical Process Blocks 

• Process Boxes 

• VSM Metrics 

• Square Wave 

• Kaizen Burst 

• Creating an Improved Process 

• Layout Diagrams and Headache Tablets 
   

Module 11: Improve Phase 

• Heijunka 

• Solutions Identified, Selected, Planned, and Implemented 

• Standardisation and Documentation 

• Communications and Training 
   

Module 12: Control Phase 

• Embed the Change 

• Measure the Gain 

• Close the Project 

What You’ll Learn in this Course

This course takes you from understanding the fundamentals of Six Sigma and Lean methodologies to applying structured process improvement techniques in real-world business settings. Each stage of the course builds your capability to analyse data, eliminate waste, and drive measurable performance improvements across operations. 
 

• Learn the core principles and framework of Six Sigma methodology 

• Learn to apply the DMAIC process for effective problem-solving 

• Learn to identify root causes and eliminate process inefficiencies 

• Learn to apply Lean and Six Sigma tools in diverse business contexts 

• Learn to measure, monitor, and sustain quality improvements over time 

• Learn to align improvements with goals and customer satisfaction 

Six Sigma Green Belt Exam Information 

To achieve the Six Sigma Green Belt, candidates will need to sit for an examination. The exam format is as follows:
 

• Question Type: Multiple Choice and Scenario Based 

• Total Questions: 30 

• Pass Mark: 70% 

• Duration: 2 Hours 

• Type: Closed Book