Introduction to Lean Six Sigma Course

Lesson 1 • The Business Case for LSS

Quantifies cost of poor quality, waste, and inefficiency to build an ROI argument. Equips learners to secure organisational buy-in for LSS initiatives.

Lesson 2 • LSS Roles and Belt Structure

Explains the Yellow, Green, Black, and Master Black Belt hierarchy and their responsibilities. Clarifies how each role contributes to project success.

Lesson 3 • Origins and Evolution of LSS

Traces Lean's roots in Toyota Production System and Six Sigma's origin at Motorola, then their merger. Provides historical grounding that frames all subsequent methodology.

Lesson 4 • Core Philosophy and Principles

Defines value, waste, variation, and customer focus as the philosophical pillars of LSS. Connects abstract principles to measurable business outcomes.

Lesson 1 • The Eight Types of Waste

Defines DOWNTIME: Defects, Overproduction, Waiting, Non-utilised talent, Transportation, Inventory, Motion, and Extra-processing. Builds a shared vocabulary for waste identification.

Lesson 2 • Waste in Service and Transactional Processes

Adapts manufacturing waste concepts to office, healthcare, and service environments. Ensures learners in non-production roles can apply LSS equally.

Lesson 3 • Waste Observation Techniques

Introduces Gemba walks, time observation sheets, and spaghetti diagrams as field tools for waste discovery. Connects observation skills to data collection in later chapters.

Lesson 1 • Voice of the Customer Methods

Teaches surveys, interviews, focus groups, and complaint analysis to capture customer needs accurately. VOC data directly drives the Critical to Quality requirements.

Lesson 2 • Stakeholder Analysis and Communication

Applies stakeholder mapping and communication planning to secure support and manage resistance. Effective stakeholder engagement is critical for project momentum.

Lesson 3 • SIPOC Diagram Development

Constructs a Suppliers-Inputs-Process-Outputs-Customers diagram to provide a high-level process view. SIPOC anchors scope discussions and guides measurement planning.

Lesson 4 • Project Selection and Scoping

Covers criteria for selecting high-impact LSS projects and avoiding scope creep from the start. Proper scoping prevents wasted effort in all subsequent phases.

Lesson 1 • Data Collection Planning

Designs structured data collection plans specifying what, where, when, and how data are gathered. A rigorous plan ensures data integrity throughout the project.

Lesson 2 • Baseline Capability and Sigma Level

Calculates process capability indices (Cp, Cpk) and converts defect rates to sigma levels. Baseline metrics set the benchmark against which improvements are measured.

Lesson 3 • Measurement System Analysis

Applies Gage R&R and attribute agreement analysis to verify that measurement systems are reliable. Unreliable measurement invalidates all subsequent analysis.

Lesson 4 • Data Types and Measurement Scales

Distinguishes continuous, discrete, nominal, and ordinal data and their implications for analysis. Correct data classification prevents analytical errors downstream.

Lesson 1 • Cause-and-Effect Analysis

Applies fishbone (Ishikawa) diagrams and the 5 Whys technique to systematically trace symptoms to root causes. Structured cause analysis prevents solution-jumping.

Lesson 2 • Hypothesis Testing Fundamentals

Covers null and alternative hypotheses, p-values, and Type I and II errors for data-driven decision-making. Hypothesis tests confirm whether observed differences are statistically meaningful.

Lesson 3 • Failure Mode and Effects Analysis

Builds a FMEA to identify, prioritise, and mitigate potential failure modes using Risk Priority Numbers. FMEA bridges analysis and improvement by targeting highest-risk causes.

Lesson 4 • Correlation and Regression Analysis

Introduces scatter plots, Pearson correlation, and simple linear regression to quantify relationships between variables. Statistical validation distinguishes true causes from coincidence.

Lesson 1 • Kaizen Events and Rapid Improvement

Plans and facilitates focused kaizen events to achieve rapid, team-driven process improvements. Kaizen events build employee engagement and deliver quick wins.

Lesson 2 • 5S Workplace Organisation

Implements Sort, Set in Order, Shine, Standardise, and Sustain to create a stable, visual workplace. 5S is the prerequisite for all other Lean improvement tools.

Lesson 3 • Flow and Pull Systems

Applies one-piece flow, takt time, and kanban to synchronise production with customer demand. Pull systems eliminate overproduction and reduce inventory waste.

Lesson 4 • Error Proofing with Poka-Yoke

Designs mistake-proofing devices and procedures to prevent defects at the source. Poka-yoke reduces reliance on inspection and human vigilance.

Lesson 1 • Statistical Process Control Charts

Constructs and interprets X-bar, R, p, and c charts to monitor process stability over time. SPC charts are the primary ongoing monitoring tool in the Control phase.

Lesson 2 • Control Plan Development

Builds a comprehensive control plan linking CTQs, control methods, response plans, and owners. The control plan is the formal handoff document to process owners.

Lesson 3 • Training and Knowledge Transfer

Designs training plans to upskill process owners and operators on new methods and controls. Effective knowledge transfer prevents regression after the project team disbands.

Lesson 4 • Project Closure and Benefits Realisation

Formalises project closure with financial validation, lessons learned, and replication planning. Closure activities ensure claimed benefits are verified and captured.

Lesson 1 • Coaching and Mentoring Green Belts

Provides Black Belt-level guidance on coaching Green Belts through project challenges and skill gaps. Effective coaching multiplies LSS capacity across the organisation.

Lesson 2 • Building a Continuous Improvement Culture

Identifies leadership behaviours, recognition systems, and infrastructure that embed CI into organisational DNA. Culture is the ultimate determinant of long-term LSS sustainability.

Lesson 3 • Facilitation and Team Dynamics

Equips learners with facilitation techniques to run productive LSS team meetings and workshops. Strong facilitation accelerates consensus and keeps projects on schedule.

Lesson 4 • LSS Deployment Strategy

Designs an organisation-wide LSS deployment roadmap aligned to strategic priorities and resource capacity. Strategic deployment maximises ROI and avoids initiative fatigue.