Green Belt Training as e-Learning

Objective: Participants will be able to define a project in such a way that it is business-relevant and measurable.

Content: Deriving critical-to-quality (CTQ) characteristics. What does the customer really want?

Lesson 1.4: SIPOC Analysis

Content: High-level process representation (supplier, input, process, output, customer).

Objective: Participants understand how to collect valid data before proceeding to analysis.

Lesson 2.1: Process representation (flowcharting)

Content: Detailed process mapping. Value-adding vs. non-value-adding activities.

Lesson 2.2: Data collection & statistics basics

Content: Data types (attributive vs. variable), sampling design, population. AI tip: The AI assistant is often asked, “How large does my sample need to be?” 

Lesson 2.3: Measurement System Analysis (MSA)

Content: Gage R&R (explained simply). Can we trust our measurements? Asset: Simple checklist: “Is my measurement system ready?”

Lesson 2.4: Process Capability (Status Quo)

Content: Calculation of cp and cpk values (introduction). Where does the process stand today (baseline)?

Objective: Participants will be able to systematically identify and prioritise potential causes before delving into statistics.

Lesson 3.1: Cause-and-effect analysis (Ishikawa & 5 Whys)

Content: Systematic brainstorming in a team. Why the 5 Whys question is often asked incorrectly.

Asset: Interactive Ishikawa template (Excel/PDF).

Lesson 3.2: Graphical data analysis (the quick glance)

Content: Pareto charts, scatter plots and box plots. Recognising patterns without complex formulas.

Lesson 3.3: Process analysis (bottleneck search)

Content: Lead time analysis, value stream focus and identification of non-value-adding steps (‘Muda’).

Objective: The participant mathematically proves which causes have a significant influence on the problem.

Lesson 4.1: Introduction to hypothesis testing

Content: Null hypothesis H0 vs. alternative hypothesis H1. What does the p-value really mean? (Explained simply for non-statisticians).

Lesson 4.2: Mean comparisons (t-test & ANOVA)

Content: When do I use which test? (Comparison of two or more groups).

Lesson 4.3: Correlation and simple regression

Content: Calculate and predict the relationship between two variables X and Y.

Objective: Separate the ‘vital few’ (the few critical causes) from the ‘trivial many’.

Lesson 5.1: Confirming the root causes

Content: Combining expert knowledge and statistical evidence.

Lesson 5.2: Preparing for the improve phase

Content: Creating a list of confirmed causes for which solutions must now be developed.

Lesson 5.3: Gate review (analyse checklist)

Content: What must be in place for the project to move on to the ‘improve’ phase?

Objective: Participants learn how to think outside the box in order to find innovative solutions for the causes identified in the analysis phase.

Lesson 6.1: Creativity techniques for engineers and managers

Content: Brainstorming, brainwriting (6-3-5 method) and the use of TRIZ principles (explained in simple terms).

Asset: ‘Idea generator’ worksheet.

Lesson 6.2: Solution selection (decision making)

Content: How to select the best solution? Cost-benefit matrix, pairwise comparison and utility analysis (Pugh matrix).

Lesson 6.3: FMEA (Failure Mode and Effects Analysis)

Content: Risk management for the new solution. What could go wrong if we implement the change?

Asset: Excel template ‘FMEA Six Sigma Europe’.

Objective: To prove that the chosen solution actually works in practice (proof of concept).

Lesson 7.1: Piloting (the field trial)

Content: Planning a controlled test. Why you should never change the entire process at once.

Lesson 7.2: Statistical confirmation of the improvement

Content: The before-and-after comparison. We use the hypothesis tests from the analyse phase to prove: ‘Yes, the process is now significantly better.’

Lesson 7.3: Change Management (The Human Factor)

Content: How do I get employees on board with the change? Recognising and resolving resistance.

Objective: Participants learn how to stabilise the new process in such a way that it is impossible to fall back into old habits.

Lesson 8.1: Standardisation (SOPs)

Content: Creation of standard operating procedures. How do you write work instructions that people will actually read? Visual management.

Asset: ‘One-page standard (visual SOP)’ template.

Lesson 8.2: Poka Yoke (error prevention)

Content: The principle of ‘foolproofing’. Examples from everyday life and industry of how to prevent errors through design (rather than through admonishment).

Lesson 8.3: Handover to the process owner

Content: The project is complete – how does the formal handover to line managers take place? Clarify responsibilities (RACI matrix).

Objective: Continuous monitoring of results and formal completion of the project.

Lesson 9.1: SPC – Statistical Process Control

Content: Introduction to quality control charts. Recognising the difference between ‘natural variation’ and ‘special causes’. When should you intervene, and when should you not?

Asset: Excel template for a simple control chart.

Lesson 9.2: Documentation & Benefit Tracking

Content: The final project report. How do you neatly calculate the success achieved (hard & soft savings) for management?

Lesson 9.3: Lessons Learned & Certification

Content: What have we learned? Outlook for the certification audit. Motivational talk: ‘You are now officially Green Belt!’