Lean Six Sigma Green Belt Course

Lesson 1 • Belt Levels and Organizational Roles

Maps White, Yellow, Green, Black, and Master Black Belt responsibilities within a deployment structure. Clarifies the Green Belt's scope and accountability on projects.

Lesson 2 • The DMAIC Roadmap Overview

Introduces Define, Measure, Analyze, Improve, and Control as a structured problem-solving cycle. Sets the stage for deep dives in subsequent chapters.

Lesson 3 • History and Evolution of Lean Six Sigma

Traces Lean's Toyota roots and Six Sigma's Motorola origins through their merger into one methodology. Provides context for why the integrated approach outperforms either alone.

Lesson 1 • SIPOC and Process Mapping

Uses SIPOC diagrams to frame the high-level process before detailed mapping begins. Establishes shared understanding of suppliers, inputs, outputs, and customers.

Lesson 2 • Stakeholder Analysis and Communication

Identifies stakeholders by influence and interest, then plans targeted communication strategies. Proactive engagement reduces resistance and accelerates project approval.

Lesson 3 • Define Phase Tollgate Preparation

Assembles all Define outputs into a cohesive tollgate package for sponsor review. Teaches criteria for a passing tollgate and how to address common gaps.

Lesson 4 • Project Charter Development

Builds each element of a project charter: problem statement, goal, scope, team, and timeline. A strong charter prevents scope creep and aligns stakeholders from day one.

Lesson 1 • Data Types and Collection Planning

Distinguishes continuous from discrete data and designs structured collection plans to minimize bias. Proper planning ensures data supports valid statistical analysis later.

Lesson 2 • Measure Phase Tollgate Preparation

Consolidates process maps, data collection results, MSA findings, and baseline capability into a tollgate package. Validates readiness to enter the Analyze phase.

Lesson 3 • Detailed Process Mapping Techniques

Introduces swim-lane flowcharts and value stream maps to expose handoffs, delays, and non-value-added steps. Detailed maps reveal hidden complexity missed in SIPOC.

Lesson 4 • Measurement System Analysis

Uses Gage R&R and attribute agreement analysis to quantify measurement error. Confirms that observed variation reflects the process, not the measurement system.

Lesson 1 • Common Statistical Tests for Green Belts

Covers t-tests, ANOVA, chi-square, and correlation tests matched to data type and question. Correct test selection ensures valid conclusions from collected data.

Lesson 2 • Hypothesis Testing Fundamentals

Explains null and alternative hypotheses, p-values, alpha risk, and beta risk in plain language. Establishes the statistical logic used in all inferential tests that follow.

Lesson 3 • Regression Analysis Basics

Introduces simple and multiple linear regression to model relationships between inputs and outputs. Regression quantifies how much each X contributes to variation in Y.

Lesson 4 • Root Cause Analysis Methods

Applies fishbone diagrams, the 5 Whys, and fault tree analysis to structure causal thinking. Structured methods prevent teams from jumping to solutions prematurely.

Lesson 1 • Lean Improvement Tools

Applies 5S, standard work, visual management, and mistake-proofing to eliminate waste and error. Lean tools deliver fast, low-cost improvements with high sustainability.

Lesson 2 • Design of Experiments Introduction

Covers full factorial and fractional factorial designs to optimize multiple process inputs simultaneously. DOE replaces one-factor-at-a-time testing with efficient, statistically valid experiments.

Lesson 3 • Solution Selection and Prioritization

Uses Pugh matrices, effort-impact grids, and weighted scoring to narrow the solution set. Objective criteria replace opinion-based decisions and build team consensus.

Lesson 4 • Piloting and Validating Solutions

Plans and executes a controlled pilot to confirm solution effectiveness before full deployment. Pilot data provides evidence for the Improve tollgate and informs the control plan.

Lesson 1 • Applying Lean in Service Environments

Adapts Lean tools to transactional, healthcare, and knowledge-work settings where waste is less visible. Service Lean requires redefining flow, inventory, and defects for non-manufacturing contexts.

Lesson 2 • Total Productive Maintenance Basics

Introduces OEE, autonomous maintenance, and planned maintenance to maximize equipment availability. TPM prevents unplanned downtime that disrupts flow and creates defects.

Lesson 3 • Value Stream Mapping in Depth

Constructs detailed current-state and future-state value stream maps with time data and inventory counts. VSM exposes the largest improvement opportunities across the entire value chain.

Lesson 4 • Flow and Pull System Design

Designs continuous flow cells and kanban pull systems to replace push-based batch production. Flow and pull reduce lead time, inventory, and overproduction waste simultaneously.

Lesson 1 • Statistical Process Control Charts

Selects and constructs I-MR, Xbar-R, p, and c charts to monitor process stability over time. Control charts distinguish common cause variation from special cause signals.

Lesson 2 • Standard Operating Procedures and Training

Documents improved processes in clear SOPs and designs training to embed new behaviors. Effective SOPs and training prevent knowledge loss when personnel change.

Lesson 3 • Mistake-Proofing and Error Prevention

Applies poka-yoke principles at the control stage to make defects physically impossible or immediately detectable. Error prevention reduces reliance on human vigilance for quality.

Lesson 4 • Project Closure and Knowledge Transfer

Formalizes project closure with financial validation, lessons learned, and replication opportunities. Structured closure ensures organizational learning is captured and shared.

Lesson 1 • Presenting Results to Leadership

Structures executive-level presentations that connect project results to financial and strategic outcomes. Clear, concise reporting builds credibility and secures resources for future projects.

Lesson 2 • Team Facilitation and Meeting Management

Applies facilitation techniques to run productive team meetings, manage conflict, and drive decisions. Skilled facilitation keeps diverse teams aligned and moving toward project milestones.

Lesson 3 • Project Selection and Scoping Criteria

Evaluates potential projects against strategic alignment, financial impact, and feasibility criteria. Selecting the right project is the single most important factor in Green Belt success.

Lesson 4 • Certification Exam Preparation

Reviews the body of knowledge tested in Green Belt certification exams and applies practice questions. Systematic review identifies knowledge gaps and builds exam-day confidence.