Interested in individual training for yourself or a small group? Learn more about our Lean Six Sigma Project Coaching Program for Individuals >>>
If you are looking for private group training for your organization, please read below…
In my experience, the most successful Lean Six Sigma training programs for both employees and companies have the following characteristics:
- Content that covers most practical Lean and Six Sigma tools
- Blended content (combination of live instructor and self-paced videos)
- Hands-on training and exercises
- Leadership support provided to participant for training and project work
- Coaching and support after training from expert
- Exam to test proficiency and knowledge retention of the content
- Requirement to complete a real-life project
- Projects benefits/results that pay for the training investment
- Aligns with ISO/CD 18404 guidance
We have a blended Lean Six Sigma training program for your organization that incorporate these key elements. See how we have helped our clients achieve amazing results with a similar program, where their project successes have paid for the training in a matter of months! (Example #1 | Example #2 | Example #3 | Example #4)
Let us guide you on a journey to transform your culture around quality and flow improvement by solving real-life projects in your organization to help transform your culture.
- 1 – Pick Your Project – Kickoff meeting and discussion with leadership and course attendees to help identify key problems to work, and understand of how the DMAIC project structure will help them improve.
- Why? This step helps inspire the team to get started on a good project. They’re often nervous about the added pressure and need validation that the project is important to their leadership team. If they aren’t important to leadership, they will not get finished or will take way too long.
- 2 – Training Camp – We provide you with the training and tools on the most common skills needed to get your team ready for success. The leader’s role is to encourage the motivate team, as it can be a lot to learn, and it will take time away from their already busy schedule. We provide a blended approach (33% self-paced training, 67% live virtual instruction for discussion and exercises).
- Why? Project leaders going through the program need to know about the tools in bite-size amounts so they are able to solve the business problem. This helps build their confidence and prepares them for the upcoming project work by showing them the pathway to success.
- Content and exercises based on traditional Six Sigma Green Belt and Lean tools:
- 60+ hours of Lean Six Sigma topics: History and Overview of Lean and Six Sigma, DMAIC, Project Charter, Data Collection, Process Mapping, 8 wastes, Statistics, Minitab, SPC, Capability, Gage R&R, Hypothesis Testing, t tests, ANOVA, Regression, DOE, FMEA, Capacity (OEE, TOC), mistake proofing, flow and pull systems, setup reduction (SMED), Standard Work, 5S and Visual Controls, Behavior Change, Daily Management System, Kaizen Events, Gemba Walks and Control Plans
- Content and exercises based on traditional Six Sigma Green Belt and Lean tools:
- Why? Project leaders going through the program need to know about the tools in bite-size amounts so they are able to solve the business problem. This helps build their confidence and prepares them for the upcoming project work by showing them the pathway to success.
- 3 – Clear the Pitfalls – Weekly calls are held to review milestones on the project checklist and overcome barriers. Weekly reports will be provided on how the teams are progressing on training and project work. When “pitfalls” arise, we work with them and their leaders to overcome and get back on track. Attendees will take a proficiency exam based on course content (must get 65% correct to pass) to ensure they understood the material.
- Why? Project leaders need support from an expert to know which tools apply and can utilize them correctly in the project. This is done through the weekly calls which helps projects stay on track when work and personal conflicts get in the way. Issues, barriers and conflicts will get escalated to the project sponsor and leadership for resolution.
- 4 – Take the Reins – Once we reach the Improve phase, and the team has a clear plan (derived from the data analysis and observations) to solve the problem, the leadership takes over to get the improvements implemented. The project team will present their findings to leadership along with the estimated impact on the problem.
- Why? The presentation provides leadership with clear direction on the project, and evidence for why the project should implement the improvements and what results will be achieved. In case funding is required, the ROI and payback calculations will be provided (capital will not be required for most projects).
- 5 – Plant the Flag – Attendees must complete a real-life project (with 10K USD/EUR expected savings or benefits). They will also be asked to submit a final presentation showing all their work which will be reviewed and approved by their coach. Upon completion of the project, a certification is awarded to the project leader(s).
- Why? Without tangible results, we won’t know if the improvements worked, and the company can recoup its investment in the training. It also allows us to recognize the hard work and accomplishments achieved for the organization, and motivate others to go on the same journey.
- Each attendee will receive up to 10 hours of coaching from instructor to help validate improvements and complete the project
- Why? Without tangible results, we won’t know if the improvements worked, and the company can recoup its investment in the training. It also allows us to recognize the hard work and accomplishments achieved for the organization, and motivate others to go on the same journey.
Each attendee will receive a Lean Six Sigma certification if they complete the following:
- Complete all training requirements (self-paced, live and recorded sessions)
- Pass the proficiency exam
- Complete a real-life project (approved internally by the Project Sponsor and BPI) and submit a project summary report showing application of tools and concepts from the course
What is the cost?
The course is $25,000 per organization (private program) for up to 10 of your employees. If only 5 employees complete a project and save only $10,000 per project, you will have a 6-month payback on your investment. I can guarantee you will have more than 50% completion rate if you follow our guidance, and you will save more than $10,000 per project on average, reducing your payback to only a few months! (Example #1 | Example #2|Example #3 | Example #4).
The cost is around $1500 per week for 16 weeks. You would pay much more than that if you had a full-time Lean Six Sigma consultant working with your team with no long-term obligation.
In-person training can also be requested, but cost will include additional time for travel and expenses. Contact us to get a quote.
Schedule time to discuss availability and get your questions answered
Program Overview
- Setup call to discuss program
- Gain internal approval for program
- Month 0
- 1-hour kickoff meeting with leadership overseeing and defining key projects
- 1-hour kickoff meeting with course attendees
- Confirm training dates
- Select improvement projects and finalize attendees
- Month 1 and 2
- Conduct virtual and self-paced training sessions (64 hours spread over 2 months to minimize disruption to their current job)
- Coaching calls every other week with individuals and teams
- Month 3
- 3 month report out to leadership team
- Coaching calls every other week with individuals and teams
- Month 4 and 5
- Coaching calls every other week with individuals and teams
- Month 6
- Final report out to leadership team
- Final presentation submission for approval
- Certification ceremony
Frequently Asked Questions (FAQ)
- What are the dates and times for the training?
- This course is private within your organization, so we will work with the attendees on the exact dates and times for the 16 sessions
- What if I miss a live class?
- Live classes will be recorded, and must be watched before you complete your certification
- What if I don’t pass the exam?
- You are able to retake the exam. It is open book, and all questions are covered in the course material
- What if I need more time or more coaching hours?
- Taking a little extra time or needing a little extra help is not a problem. If you need a lot more assistance, there are options available to extend or add on additional hours. Please discuss with us during your next coaching call.
- What happens after I complete my certification?
- You are eligible to attend our Black Belt training, which is a similar program, but with more advanced training material and higher expectations for project benefits (50K USD/EUR per project)
- Can I work with someone else on a project?
- Yes, you can partner with another employee, but the total project benefits will need to be double, so you both average the minimum amount of savings. Each person must also equally contribute to the project (based on feedback from the other person).
- What if I don’t have others in my organization interested in the training?
- Check out our coaching program for individuals
- What is the payment plan?
- We will require a signed purchase order before the training begins, with 50% of the payment made within 30 days of the first training date. After the training is completed, and projects have been launched and coaching sessions are underway, we will ask for the remaining 50% payment (around month 3). We can also work with you on payment options ($6500 per month for 4 months).
- What is different about this program if we request Black Belt training instead of Green Belt?
- In order to attend Black Belt, all attendees must have completed a qualified Green Belt training program (which covers key topics to help prepare you for the Black Belt training, and preferably with a completed Green Belt project). Otherwise, there will be extra cost added to include the Green Belt material, or the team should start with the Green Belt program first.
- In addition, there will be additional project benefits required for a Black Belt project (50K USD/EUR per project), a requirement to provide training on some Green Belt tools and methods to others at your facility, along with providing mentoring to other employees on a Green Belt project or Lean event. The cost of the program will increase to $30,000 to accommodate these additional requirements.
- What statistical software program is required for the program?
- The program is built around Minitab (recommended), but can be taught with Excel add-ins, SigmaXL, QI Macros, JMP, R, KNIME or other statistical package. It is ideal to purchase full licenses for attendees instead of relying on free trials of the software, so they can use the program during their project. We can also run analysis for you if you lose access to your program. Additional fees may be added for modifying the training for lesser known packages.
- What are the differences between the Individual program and the Organization program?
- The Individuals program is a little lighter in the content, and also takes less time to complete the training. The courses are all online and self-paced (no live instructor), whereas the Organization program is a blend of live instruction, live coaching and self-paced online training. The cost reflects the additional amount of training hours and coaching support, along with time spent working with management to select good projects and provide weekly updates.