The course combines the quality management methods KAIZEN, Lean, KVP, and Six Sigma, and provides various basic principles, tools, and methods for improving product, process, and service quality in companies. It begins with an introduction to Six Sigma—from the basics to the implementation of more complex Six Sigma projects in companies, incorporating AI-supported methods. It then covers KAIZEN (Japanese: KAI for “change” and ZEN for “for the better”), the Lean philosophy, and the continuous improvement process (CIP).
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Certificates: Certificate "Six Sigma Green Belt with Lean, Kaizen and CIP"
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Additional Certificates: Certificate "Process optimization with Lean, Kaizen and CIP"
"Six Sigma Green Belt" Certificate -
Examination: Praxisbezogene Projektarbeiten mit Abschlusspräsentationen
Six Sigma 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
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
Quality Management – Six Sigma Green Belt
Introduction to Six Sigma (approx. 1 day)
What is Six Sigma? History, Philosophy, and Strategy
DMAIC Project Phases, Objectives, and Roles
Six Sigma in the Context of Lean, Quality Management, and Operational Excellence
Hybrid Project Management with DMAIC for AI Projects
AI-Powered Project Management (approx. 1 day)
Fundamentals of Artificial Intelligence
Applications Along the DMAIC Framework, Limitations, and Risks
Data and Prompt Fundamentals, Context, and Quality Criteria
Governance, Security, the EU AI Act, and the GDPR
AI Dashboard, Information Consolidation, and Quality Gates
Define – Define (approx. 3 days)
Project identification, strategic relevance, and key metric driver tree
Distinction from CIP and PUL (Problem, Cause, and Solution)
Project Profile: Problem Description and SMART Goal Definition
In-scope and out-scope definitions, as well as AI-supported completeness check
LIPOK and Voice of the Customer (VoC)
Affinity Diagram and Kano Model
VoC-to-CTQ transformation, specifications, and acceptance criteria
AI-supported analysis and technical validation of customer requirements
Cost-effectiveness: ROI, TCO, and qualitative benefits
Stakeholder Analysis and AI-Supported Project Planning
Risk Analysis and Preventive Measures
Change management and motivation for change
Communication strategy, elevator pitch, and AI-supported change story
Quality Gate Review: Define
Measure – Measurement (approx. 3.5 days)
Mathematical process model and cause-and-effect chain of the CTQs
Influence analysis using Ishikawa and KSR, as well as an AI-supported metrics matrix
Data Types and Measurement Scales
Operational definition, data collection methods, and sampling strategy
Data collection plan and control using an AI dashboard
Measurement system analysis: bias, repeatability, reproducibility, and gage R&R
Data quality, plausibility checks, and AI-supported data cleaning
Data Visualization, Statistical Metrics, and Machine and Process Capability
AI-Supported Interpretation of Measurement Results and Quality Gate Review Measure
Analyze – Analysis (approx. 3.5 days)
Process Map and Data Map, as well as Value Stream Analysis
Value stream analysis, spaghetti diagram, TIMWOODS, and Makigami
Distinguishing Between Symptoms, Problems, and Causes
Cause-and-effect and Pareto analysis, as well as AI-supported error code clustering
Hypothesis Formulation and AI as a Sparring Partner
Design of Experiments and AI-assisted testing of influencing factors
Correlation and regression analysis, as well as statistical hypothesis testing and group comparisons
AI-Supported Evidence Matrix and FMEA
Quality Gate Review and Analysis
Improve – Innovative Improvement (approx. 3 days)
Creativity Techniques and AI-Supported Solution Development
Lean solution principles as well as technical and organizational measures
Solution approaches using generative AI, automation, and robotics
Regulatory and organizational requirements for AI deployment
AI-specific risk assessment, as well as feasibility and maturity analyses
Solution evaluation
Acceptance and cost-benefit analysis
Implementation plan and pilot program with success and acceptance criteria
Iterative Approach to AI Pilots and Quality Gate Review Improve
Control – Controlling and Sustainable Implementation (approx. 2 days)
Go-Live, Process Stabilization, and Support During the Start-up Phase
Standard Operating Procedures and Controlling Plan
KPIs, statistical process control, control charts, and corrective actions
Balanced Scorecard and AI-Supported Monitoring
Audit Concept
Project completion, handover, and AI-supported documentation
Quality Gate Review Control
Project work, exam preparation, and final exam (approx. 3 days)
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.
As a Six Sigma project manager, you will also enhance your career profile across all industries.
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).