Yellow Belt Body of Knowledge

Module 1: Six Sigma Fundamentals

Six Sigma Foundations and Principles: DMAIC methodology and its impact on quality.
Lean Foundations and Principles: Waste elimination techniques like JIT, 5S, VSM.
Six Sigma Roles: Overview of belts, champions, sponsors.
Quality Tools: Pareto chart, fishbone, check sheet, histogram, etc.

Module 2: Define Phase

Project Identification
VOC & CTQ: Understanding customer needs.
Project Selection: Choosing suitable Six Sigma projects.
Stakeholder Analysis
SIPOC: Mapping suppliers, inputs, process, outputs, customers.

Module 3: Measure Phase

Basic Statistics: Mean, median, std. dev, variance.
Data Collection: Plans, techniques, frequency.
Qualitative vs Quantitative Data
MSA & GR&R: Measurement reliability checks.

Module 4: Analyze Phase

Lean Tools: 5S, value analysis.
FMEA: Risk analysis through severity, occurrence, detection.
Root Cause: 5 Whys, fishbone, matrix analysis.
Regression & Correlation
Hypothesis Testing: Basics of testing assumptions.

Module 5: Improve & Control Phase

Kaizen & PDCA: Continuous improvement models.
Cost-Benefit Analysis
Control Plans & Charts: Sustainability tools.
Documentation: Ensuring clarity and communication.

Green Belt Body of Knowledge

Foundations & Organizational Alignment

Value of Six Sigma: History and purpose. Quality philosophies of Juran, Deming, Shewhart, Ishikawa.
Organizational Goals: How Lean Six Sigma supports strategic goals.
Organizational Drivers & Metrics: Profitability, market share, customer satisfaction, Balanced Scorecard.
Lean Principles: Value, flow, 7 wastes, and 3Ms (Muda, Mura, Muri).
Design for Six Sigma (DFSS): Overview of DMADV and IDOV approaches.

Define Phase

Project Identification: Selection process, stakeholder analysis.
Voice of Customer & Business: CTQ Tree, Cost of Poor Quality.
Project Charter & SIPOC: Key tools to initiate projects.

Team Management & Planning

Team Communication: Communication plans, team dynamics.
Roles & Responsibilities: Brainstorming, NGT, Multi-voting.
Planning Tools: Affinity, tree, interrelationship diagrams, PDPC, matrix diagrams, activity networks.

Measure Phase

Basic Statistics: Descriptive & inferential, CLT, distributions.
Probability: Independent/mutually exclusive events, permutations & combinations.
Process Characteristics: Flow metrics, process mapping tools.
Data Collection: Types, scales, sampling, methods.
MSA: Bias, linearity, stability, Gage R&R, P/T Ratio.
Process Capability: Cp, Cpk, Pp, Ppk, DPMO, PPM, ST vs LT capability.

Analyze Phase

Relationships Between Variables: Correlation, linear regression.
Hypothesis Testing: Means, variances, proportions, ANOVA, chi-square.
FMEA: PFMEA and DFMEA techniques.
Other Tools: Root Cause Analysis, Waste Analysis, Why-Why.

Improve & Control Phase

DOE (Design of Experiments): Basics, main & interaction effects.
Lean Tools: 5S, Kanban, Standard Work, SMED, Kaizen, Continuous Flow.
Pilot Implementation: Strategies for rollout.
SPC Basics: Variable selection, control chart types, subgrouping, chart analysis.
Other Controls: TPM, Poka Yoke, Visual controls, Control Plan.

Black Belt Body of Knowledge

Module 1: Introduction

Fundamentals: Six Sigma, Lean, Continuous Improvement Methodologies
Business Systems & Processes: Strategic planning, Deployment
Leadership: Roles, Roadblocks, Change management
Organizational Process Management: Stakeholder analysis, Benchmarking, Financial & performance measures
Team Management: Formation, Facilitation, Dynamics, Training

Module 2: Define Phase

Voice of Customer (VOC): Identification, Data collection, Requirements
Business Case & Project Charter: Scope, Goals, Performance metrics, Review
Project Management Tools: Gantt chart, WBS, RACI, Toll-gate reviews
Analytical Tools: Affinity diagrams, Tree diagrams, Prioritization matrices, Matrix & Activity network diagrams

Module 3: Measure Phase

Process Characteristics: Flow metrics, Analysis tools
Data Collection: Data types, Scales, Sampling, Collection methods
Measurement Systems: MSA, Organizational-level measurement, Metrology
Basic Statistics: Descriptive statistics, CLT, Graphical methods, Valid conclusions
Probability: Core concepts and distributions
Process Capability: Cp, Cpk, Pp, Ppk, Non-normal data, Attributes data, ST vs LT capability

Module 4: Analyze Phase

Relationships Between Variables: Correlation, Regression, Multivariate tools
Hypothesis Testing: Means, Variances, ANOVA, Chi-square, Nonparametric tests, Practical vs statistical significance
FMEA: Failure Modes for process and design
Other Tools: Gap Analysis, RCA, Waste Analysis

Module 5: Improve Phase

DOE: Terminology, Design planning, One-factor, Fractional & Full factorial experiments
Lean Methods: Waste elimination, Cycle time, Kaizen, TOC, OEE, Pilot implementation

Module 6: Control Phase

SPC: Objective, Variable selection, Subgrouping, Control chart selection & analysis
Other Controls: TPM, Visual controls
Maintain Controls: Control plan
Sustain Improvements: Documentation, Training, Evaluation, Lessons learned

Module 7: Design for Six Sigma (DFSS)

Common DFSS Methodologies: DMADV, IDOV
Design for X (DFX): Reliability, Maintainability, Safety, Cost, etc.
Robust Design: Methods to ensure product/process stability

Lean Champion Body of Knowledge

Introduction to Lean Philosophy

✅ Origin and evolution of Lean

✅ Principles of Lean Thinking

✅ Lean vs Traditional manufacturing

✅ Overview of benefits for MSMEs

✅ Role of Lean Champions in transformation

✅ Identifying waste (Muda), variability (Mura), and overburden (Muri)

5S System for Workplace Organization

✅ Sort, Set in Order, Shine, Standardize, Sustain

✅ Implementation roadmap

✅ Benefits to productivity, safety, and morale

✅ Conducting 5S audits and sustaining practices

Visual Management & SOP Development

✅ Visual tools: signs, indicators, lane markings, Poka-Yoke visuals

✅ Creating Standard Operating Procedures (SOPs)

✅ Ensuring consistency and reducing reliance on individuals

Flow & Pull Systems

✅ Just-in-Time (JIT) principles

✅ Kanban systems to control production and inventory

✅ Cycle time optimization and process balancing

Cellular Manufacturing & Value Stream Mapping

✅ Cellular layout design for process families

✅ Identifying value-added vs non-value-added activities

✅ Drawing current and future state Value Stream Maps

Mistake Proofing & SMED

✅ Poka-Yoke techniques for error prevention

✅ Single Minute Exchange of Dies (SMED)

✅ Setup time reduction and flexibility in production

Total Productive Maintenance (TPM)

✅ TPM pillars and structure

✅ Role of operators in proactive maintenance

✅ Improving Overall Equipment Effectiveness (OEE)

Kaizen & Rapid Improvement

✅ Kaizen mindset and team involvement

✅ Planning and executing Kaizen Blitz

✅ Capturing results and standardizing gains

Quality Tools & Low-Cost Automation

✅ 7 QC Tools for root cause analysis and quality improvement

✅ Jidoka (Autonomation) for in-line quality control

✅ Examples of Low-Cost Automation in Lean

Level Scheduling & Lean Deployment

✅ Hinjunka (Level Scheduling)

✅ Reducing lead times and batch sizes

✅ Lean implementation roadmap for MSMEs

✅ Sustaining gains through culture and leadership

5S Auditor Body of Knowledge

Module 1: Introduction to 5S Methodology

✅ What is 5S? History & Origin

✅ Importance of 5S in Workplace Organization

✅ Benefits of 5S Implementation

Module 2: Understanding the 5S Framework

✅ Sort (Seiri): Eliminating unnecessary items

✅ Set in Order (Seiton): Organizing tools & equipment

✅ Shine (Seiso): Cleaning & maintenance best practices

✅ Standardize (Seiketsu): Establishing procedures for sustainability

✅ Sustain (Shitsuke): Developing habits for long-term effectiveness

Module 3: Implementing 5S in Different Industries

✅ 5S in Manufacturing & Production

✅ 5S in Service Sectors & Office Workspaces

✅ Case Studies & Success Stories

Module 4: Conducting a 5S Audit

✅ What is a 5S Audit?

✅ Steps to Conduct an Effective 5S Audit

✅ Tools & Checklists for 5S Audits

✅ Common Challenges & How to Overcome Them

Module 5: Performance Measurement & Continuous Improvement

✅ Metrics & KPIs for 5S Implementation

✅ Integration of 5S with Lean & Six Sigma

✅ Sustaining a 5S Culture in an Organization

Module 6: Examination & Certification

✅ Exam Format: MCQs & Case Study-Based Questions

✅ Minimum 60% Required to Pass

✅ Two Attempts Allowed

✅ Certification Issued by the Government of India

Why Choose This Course?

✅ Industry-Relevant Training

✅ Practical Insights with Case Studies

✅ Learn from Experts in Lean & Six Sigma

✅ Official Government Certification

VisionExcellence Consulting Private Limited

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Government of India

MSME – Technology Development Centre, Chennai

Mastering the Process Efficiency

Dr.Gopal Sivakumar

Lean Six Sigma for Professionals

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Yellow Belt Body of Knowledge

Module 1: Six Sigma Fundamentals

Module 2: Define Phase

Module 3: Measure Phase

Module 4: Analyze Phase

Module 5: Improve & Control Phase

Green Belt Body of Knowledge

Foundations & Organizational Alignment

Define Phase

Team Management & Planning

Measure Phase

Analyze Phase

Improve & Control Phase

Black Belt Body of Knowledge

Module 1: Introduction

Module 2: Define Phase

Module 3: Measure Phase

Module 4: Analyze Phase

Module 5: Improve Phase

Module 6: Control Phase

Module 7: Design for Six Sigma (DFSS)

Lean Champion Body of Knowledge

Introduction to Lean Philosophy

5S System for Workplace Organization

Visual Management & SOP Development

Flow & Pull Systems

Cellular Manufacturing & Value Stream Mapping

Mistake Proofing & SMED

Total Productive Maintenance (TPM)

Kaizen & Rapid Improvement

Quality Tools & Low-Cost Automation

Level Scheduling & Lean Deployment

5S Auditor Body of Knowledge

Module 1: Introduction to 5S Methodology

Module 2: Understanding the 5S Framework

Module 3: Implementing 5S in Different Industries

Module 4: Conducting a 5S Audit

Module 5: Performance Measurement & Continuous Improvement

Module 6: Examination & Certification

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