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Course overview   

The objective of the Six Sigma improvement approach is to reduce variation in processes, allowing a more predictable output. Industry Forum believes that Six Sigma improvement activities are most effective in environments where a foundation level of stability has already been established through Lean or Total Productive Maintenance programmes. Six sigma builds on these foundations to analyse and eliminate the causes of variation that remain, using a structured approach and toolkit. The six sigma 'Green Belt' is designed for those who will lead local area improvement activities or participate in larger, business wide projects.

Industry Forum has developed a Six Sigma Green Belt training programme for companies who wish to develop their capability in this area, aligned to the ISO-13053 international standard. We recognise that wherever possible training should be through a 'learn by doing' approach with coaching and mentoring support in preference to classroom based education. With this in mind, Industry Forum has developed a Six Sigma Green Belt programme that introduces the critical programme elements within the classroom and simulation environment whilst maximising the time spent coaching learners during project delivery.

Who should attend?   

Suitable for all delegates such as Project Managers, Manufacturing Engineers, Quality Engineers and Supplier Development Engineers who are required to solve complex problems using the Define - Measure - Analyse - Improve - Control (DMAIC) Process.

Topics covered   

To make the six sigma approach more accessible the Industry Forum Green Belt programme is built around the use of Microsoft Excel software rather than Minitab statistical software. The programme comprises five days training supported by coaching, mentoring and assessment support as shown below. The training phase is phased over a two month period with coaching activities taking place between sessions:

Day one Introduction -

  • Six Sigma Overview, Structure and ISO Standard
  • Introduction - Certification Requirements
  • Define - Critical To Quality Characteristics (CTQCs) and Voice Of Customer (VOC), Project Charters (Project Refinements), SIPOC and Process Mapping, Cause and Effect Matrix, Waste and Value Analysis

Day two

  • Define - Failure Mode and Effect Analysis (FMEA)
  • Measure - Data Types - Distribution Curves - Sampling, Data Collection Plan, Measurement System Analysis

Day three

  • Analyse - Capability, Data Trails and Charts, Cause and Effect Diagram / 5 Why Analysis

Day four

  • Improve - Mistake Proofing, Alternative Idea Generation, Solution Selection, Pilot and Validate Improvements
  • Control - Statistical Process Control (SPC), Standard Work

Day five

  • A review of the DMAIC process and tools used, a final exam which is based on this 5 day training programme, a review of individual project and discussion on next steps

Project Selection

To receive Green Belt certification, each learner will need to pass the end of training knowledge examination and to then complete a Green Belt standard project. Learners should identify a suitable project with their line manager prior to the first training session. Following the first training phase this can then be developed into the formal project charter.

A good green belt project should: 

  • Be aligned to the working environment of the learner
  • Be targeted to close a gap between current and business target performance in a business process, where a tangible financial impact of improvement can be determined
  • Tackle a problem where the cause of the problem or gap is not clearly understood
  • Not have a defined solution easily identifiable
  • Be suitable for data analysis activities to measure and analyse the problem
  • Show evidence of process variation or inconsistent performance
  • Be suitable for completion within the required timescale
  • Be in an area where the learner can make change happen and will be able to implement improvements
  • Have support resource available to assist the learner if required in delivering the project

Project Support and Certification   
It is typically anticipated that learners complete the Green Belt project over three to four months after the initial training. Industry Forum supports learners during this implementation phase through a combination of group coaching and individual reviews. This ensures that learners can complete each phase of their projects to a strong standard and be confident that the phase outputs will support the next stage of activity.Where learners are based remotely from the main training location, this may include internet based communication such as Skype or 'Go To Meeting' to minimise travel implications.

Why choose Industry Forum?   

Industry Forum helps major global manufacturers understand, optimise and improve both manufacturing capability and business performance.

An integrated team of consultants and practitioners – all seasoned expert engineers with multi-sector manufacturing experience – Industry Forum brings together a world-class combination of improvement competency, insight, process and best practice.

Spanning automotive, aerospace, consumer appliance, electronics and food sectors, for over 20 years Industry Forum has planned and delivered some of the world’s most consistent and successful transformations for business-critical manufacturing operations.

Our trainers are expert practitioners with hands-on industrial experience and highly developed communication skills.

They have a wealth of technical expertise and often provide on-site advice and coaching. During every course we will encourage collaboration and sharing of practical experiences, ensuring learning can be put into context and empowering delegates to apply their new skills successfully in their workplace as well as making sustainable improvements.

This course is run in-house. Please contact us to arrange a confidential discussion around your needs.

Further information