Six Sigma & Lean Green Belt

Gain a sound understanding of the efficient design, planning and control of production and logistics systems or factory structures. Our programme aims to provide you with the essential analytical skills needed to effectively design and improve both new and existing production processes and logistics structures, using our 200m² lean learning factory to combine theoretical knowledge with practical experience. This enhances your analytical thinking and strengthens your ability to solve complex, interdisciplinary problems by seamlessly combining theory and practice.

Specific module content:

• Product development process and simultaneous engineering, product lifecycle management
• Business process reengineering, Six Sigma, change management, FMEA, key figures
• Factory planning
• PPS, MES, Heijunka, Kanban board
• Production planning: Cycle planning, workstation design for final assembly
  and a batch size-orientated punching workstation
• Logistics planning: route traffic, milk run, setting up Kanban cycles
  , setting up C-parts management, warehouse structure
• Setting up JIT cycles, data connection for sequence
  creation and call-off system, etc.
• Live operation of the lean learning factory by the participants

Afterwards, you will go to our model and learning factory for practical training: In this seminar, you will experience an innovative learning method, problem-orientated learning. As a participant, you will be directly involved in a real-life scenario: You will work on setting up a branch for the company "Dolly International Inc.", which specialises in the production of floor rollers. This gives you the opportunity to apply the theory you have learnt directly in practice and develop problem-solving skills.

You will be assigned to one of 13 specialised departments where you will take on different but essential tasks. From planning factory structures and assembly cells to creating work schedules and optimising production processes through Kanban cycles, route traffic and just-in-time deliveries - you will go through all phases of production planning.

In your department, you will present your planning results and investment requirements in a 30 to 45-minute presentation. This not only develops your presentation skills, but also enables intensive dialogue and learning within your peer group.

The highlight of the seminar is the comparison of your planning results with the real model factory in the PuLL competence centre. Here you will analyse differences and put the planning into practice. The group will first operate the model factory in the traditional workshop layout and then in the lean-orientated layout. This offers you an invaluable opportunity to recognise the core differences between the two approaches and to develop a deep understanding of lean management

The training module Quality with Six Sigma teaches the knowledge and skills for process optimisation using Six Sigma - both in the context of industrial production and in the service environment. You will receive the appropriate methodological tools to be able to solve problems and issues in your own company environment.

The contents of the module are as follows

• Integration of Six Sigma into the process optimisation and quality management environment
• Introduction to Six Sigma: history, roles, management of Six Sigma / process optimisation projects and teams, comparison with other methods)
• Six Sigma system and possible applications
• Define phase: Process and tools used, e.g. presentation of the current situation, project order, SIPOC, VOC
• Measure phase: Process and required tools such as process capability indicators, process mapping, root cause analysis, statistical tools, data collection, measurement system analysis
• Analyse phase: Procedure, required tools such as data analysis, application of data representations, hypothesis tests, regression and ANOVA
• Improve phase: process, solution development, selection, refinement and implementation
• Control phase: transfer to routine, monitoring and maintaining the quality status