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Certificates: Certificate "Six Sigma Green Belt with Lean, Kaizen and CIP"
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Additional Certificates: Certificate "Six Sigma Yellow & Green Belt"
Certificate "Process optimization with Lean, Kaizen and CIP" -
Examination: Praxisbezogene Projektarbeiten mit Abschlusspräsentationen
„Six Sigma Yellow & Green Belt” -
Teaching Times: Full-timeMonday to Friday from 8:30 a.m. to 3:35 p.m. (in weeks with public holidays from 8:30 a.m. to 5:10 p.m.)
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Language of Instruction: German
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Duration: 8 Weeks
Quality management - Six Sigma Yellow & Green Belt
Six Sigma Yellow Belt (approx. 1 week)
Introduction to the Six Sigma strategy - Yellow Belt (approx. 1.5 days)
What is Six Sigma? History and philosophy
DMAIC project phases at a glance and their individual objectives
Roles and responsibilities
Six Sigma in the context of lean and QM (OpEx)
AI as an assistant for structuring the project objective, scope and stakeholders
AI in the improvement project (approx. 0.5 days)
Types of AI (ML,DL,LLM,GenAI)
Data and prompt basics
Governance and security
Define phase (approx. 0.5 days)
Problem and project definition (Project Charter)
Understanding customer requirements (VOC-CTQ)
Process mapping (SIPOC)
Operational definition and data quality
AI-supported clustering of simple VOC examples
Measure phase (approx. 0.5 days)
Process mapping (flow chart and swimlane)
Insight into measurement system analysis (MSA)
Basic key figures (DPMO, Sigma Level)
Data types and collection (graphical analyses)
AI for measurement plan checklists, plausibility checks
Analysis phase (approx. 1 day)
Cause-effect analysis (5-Why, Ishikawa)
Basics of statistical methods
Insight into machines and process capability
Improve phase (approx. 0.5 days)
Generate solution ideas (Poka Yoke)
Risk assessment and introduction of FMEA
Control phase (approx. 0.5 days)
Definition of process monitoring (control plan)
Insight into statistical process control (SPC)
Process documentation and standardization (SOP)
Six Sigma Green Belt (approx. 3 weeks)
Project management with Six Sigma - Green Belt (approx. 1 day)
Green Belts as project managers
Work breakdown structure (WBS), project communication and documentation
Teamwork and leadership
Going through DMAIC project phases using advanced statistics application tools and methods
AI-supported project management: risks/dependencies, schedule risk analysis
Define phase (approx. 1.5 days)
Project profile, business case
Project scoping, stakeholder and risk analysis
VOC in CTQ transformation (CTQ tree)
Team composition, project planning (Gantt chart, milestone planning)
Cost calculation and target formulation (benefit)
Measure phase (approx. 2.5 days)
Advanced statistical basics
Visualization and interpretation (histogram, run chart, box plot)
Short-term vs. long-term capability (MFU, PFU)
Calculation and interpretation of the sigma level
Process indicators (Pp, Ppk, Cp, Cpk)
Measurement system analysis (MSA), bias, gage R&R
AI-supported data checks (missing values, outlier indications)
Analysis phase (approx. 4 days)
Hypothesis development, correlation analysis
Correlation (Pearson) and analysis of variance (ANOVA)
Lean time and value flow (yield, OEE, VSM)
Text/error code clustering for Pareto according to failure modes with AI
Improve phase (approx. 1 day)
Design of Experiments (DoE)
Solution generation and creativity methods (mind mapping, brainstorm/writing, 6-3-5 method)
Testing (Poka Yoke, piloting, cost-benefit analysis)
Risk minimization (FMEA, RPN evaluation)
Implementation
Control phase (approx. 1 day)
Sustainable implementation (control plan)
SPC, quality control charts (X̄-R chart, X̄-s chart)
Process monitoring (KPI, dashboard, BSC)
Project completion and handover
AI-supported KPI story/management summary
Project work, certification preparation and certification examination (approx. 4 days)
Process optimization with Lean, Kaizen and CIP
What is CIP/Kaizen/Lean? (approx. 0.5 days)
Definition, goals, benefits (CIP vs. Kaizen vs. Lean)
Principle of small steps
Historical development of the CIP (approx. 1 day)
Supply/demand orientation
Japanese corporate culture
Toyota Production System
Development of modern quality and management systems (e.g. TQM)
Overview of maturity level and assessment models (EFQM)
Framework conditions for successful CIP (approx. 0.5 days)
Role of management
Communication and transparency
Employee participation
Corporate culture and motivation
Interface and team management
Quality management principles (e.g. ISO 9001)
Philosophy of CIP/Kaizen (approx. 1 day)
The five central principles
Internal customer/supplier principle
Interaction of innovation, standard and kaizen
Tasks of management and employees
Customer requirements and satisfaction (approx. 1.5 days)
Market and stakeholder analysis
Kano model
Requirements and wishes
CTQ methods (Translation Matrix, CTQ Tree)
Vuca and agility
Integrated management systems
Process optimization: Efficiency for the benefit of customers - Lean management: Value and waste (approx. 1 day)
Philosophy: Focus on customer requirements
Productivity - Quality - Availability - Flexibility
Value creation and non-value creation
The 7 types of waste (TIMWOOD)
3 MU: Muda, Mura, Muri
Implementation of Kaizen and CIP (approx. 1 day)
Prerequisites for Kaizen in the company
Development of a continuous improvement culture
5S method/5A campaign
Kaizen as a management system
Kaizen roadmap
Synchronize processes (approx. 0.5 days)
Production in the customer cycle
Cycle time, cycle time, throughput time
Cell logic
One-piece flow
Pull principle (supermarket) and push principle
Just-in-time logistics [JIT]
Value stream analysis (approx. 0.5 days)
Value stream mapping (actual and target value stream)
Value added quotient [WQ]
Visualization: benefits, symbols, data box
Level production/Heijunka (approx. 0.5 days)
Heijunka vs. series
Heijunka box
Batch size 1
Application example
Increasing the number of cycles
Kanban flow system (material and information flow)
Improve production facilities (approx. 0.5 days)
Total Productive Maintenance (TPM) incl. autonomous maintenance
Key process indicators (KPIs, OEE)
Minimization of set-up times (SMED)
Standardize processes (approx. 1 day)
Quality policy standardization
Advantages of standards
Standards in the company
Questions about the standard
Defining processes, from the process landscape to the process description
Visualization
3 process states
Worker self-check
Controlling processes (approx. 2.5 days)
ISO 9001 requirements (4.4, 8.1, 8.5.1): Customer key figures (Cpk/Sigma level)
Process management
Process analysis
Standard tools: Q7 and M7
Process efficiency analysis
AI-supported data analysis, statistical process control [SPC]
SPC in series production: interpreting quality control charts [QRK], automation (Jidoka)
Evaluation models (approx. 1 day)
PDCA: Improvement of improvement
Self-assessment maturity level ISO 9004 and EFQM
Management assessment according to ISO 9001
6-W questioning technique
4-M/7-M checklists
Benchmarking and best practice
Balanced Scorecard (BSC)
Hoshin Kanri, X-Matrix
AI-supported evaluation of trends, key figures and assessments
Measurement of customer and employee satisfaction
Error prevention and systematic problem solving (approx. 2 days)
Development according to customer requirements
Risk management: risk landscape, matrix [FMEA]
Poka Yoke, error classification, error culture/Hansei
Internal audits
Customer communication: complaint management, 8D report
10 steps to problem solving with tools (Q7, M7)
Root cause analysis: 5 Why, 6 W (Root Causes)
A3 problem solution sheet
AI-based pattern recognition for error and quality data
Empowering employees (approx. 1 day)
Ownership and entrepreneurship
Roles of managers and employees
Change management
Promoting employees (TWI)
Employee satisfaction
Competence and awareness, knowledge management (ISO 9001)
Idea management (BVW)
Teamwork in a lean context
Quality Circle [QC]
Agile methods
Community of Practice (CoP)
Coaching Kata and Improvement Kata
Visual Management and Shopfloor (approx. 0.5 days)
Principles of visual control
Visual process control, Andon (traffic light)
Store floor management
Digital dashboards and AI-supported process visualization
Quality controlling - finances (approx. 0.5 days)
Quality cost model, conformity/defect costs, rule of 10 (as a mental model)
Project work (approx. 3 days)
To consolidate the content learned
Presentation of the project results
Changes are possible. The course content is updated regularly.
You recognize the permanent opportunity for improvement based on the Kaizen philosophy and CIP, have the necessary expertise to implement these improvements and have the right understanding of a functioning lean philosophy in the company. You can also implement Six Sigma projects independently and successfully in accordance with ISO 13053-1 (DMAIC). You will be able to apply the specific tools and methods with confidence and thus implement complex improvement projects responsibly.
Specialists and managers from the areas of quality and process management as well as those responsible for change processes.
Process optimization specialists are in high demand across all industries and are among the most important specialists in modern companies.
Your meaningful certificate provides a detailed insight into the qualifications you have acquired and improves your career prospects.
Didactic concept
Your lecturers are highly qualified both professionally and didactically and will teach you from the first to the last day (no self-study system).
You will learn in effective small groups. The courses usually consist of 6 to 25 participants. The general lessons are supplemented by numerous practical exercises in all course modules. The practice phase is an important part of the course, as it is during this time that you process what you have just learned and gain confidence and routine in its application. The final section of the course involves a project, a case study or a final exam.
Virtual classroom alfaview®
Lessons take place using modern alfaview® video technology - either from the comfort of your own home or at our premises at Bildungszentrum. The entire course can see each other face-to-face via alfaview®, communicate with each other in lip-sync voice quality and work on joint projects. Of course, you can also see and talk to your connected trainers live at any time and you will be taught by your lecturers in real time for the entire duration of the course. The lessons are not e-learning, but real live face-to-face lessons via video technology.
The courses at alfatraining are funded by Agentur für Arbeit and are certified in accordance with the AZAV approval regulation. When submitting a Bildungsgutscheinor Aktivierungs- und Vermittlungsgutschein, the entire course costs are usually covered by your funding body.
Funding is also possible via Europäischen Sozialfonds (ESF), Deutsche Rentenversicherung (DRV) or regional funding programs. As a regular soldier, you have the option of attending further training courses via Berufsförderungsdienst (BFD). Companies can also have their employees qualified via funding from Agentur für Arbeit (Qualifizierungschancengesetz).