Six Sigma Yellow Belt Training Course

1. Introduction to Six Sigma and Quality Foundations

1.1 Six Sigma Overview

• Six Sigma philosophy and benefits including (customer focus, defect reduction, cost savings)

• Quality evolution including (inspection, quality control, quality assurance, total quality management)

• Six Sigma hierarchy including (Champion, Master Black Belt, Black Belt, Green Belt, Yellow Belt)

• Business impact including (productivity improvement, customer satisfaction, competitive advantage)

• Introduction to ASQ Body of Knowledge and IASSC standards for Yellow Belt practitioners

1.2 Quality Fundamentals

• Quality definitions including (fitness for use, conformance to requirements, customer satisfaction)

• Quality characteristics including (performance, reliability, durability, serviceability)

• Cost of quality including (prevention costs, appraisal costs, failure costs)

• Customer requirements including (voice of customer, critical to quality, specifications)

• Process thinking including (inputs, outputs, suppliers, customers, value-added activities)

2. Basic Statistics and Data Analysis

2.1 Statistical Concepts

• Data types including (continuous, discrete, attribute, variable)

• Basic statistics including (mean, median, mode, range, standard deviation)

• Data collection including (sampling, measurement, data recording, data validation)

• Data presentation including (tables, graphs, charts, visual displays)

• Normal distribution including (bell curve, standard deviations, probability)

2.2 Basic Statistical Tools

• Descriptive statistics including (central tendency, variability, frequency distributions)

• Histograms including (data distribution, pattern identification, process understanding)

• Pareto analysis including (80/20 rule, prioritization, vital few)

• Scatter plots including (correlation, relationships, cause-and-effect)

• Basic probability including (probability concepts, random events, statistical thinking)

3. DMAIC Methodology Fundamentals

3.1 Define Phase Basics

• Problem identification including (problem statements, project scope, objectives)

• Project charter elements including (business case, team members, timeline)

• SIPOC overview including (suppliers, inputs, process, outputs, customers)

• Voice of customer basics including (customer needs, requirements, expectations)

• Team roles including (team member responsibilities, communication, participation)

3.2 Measure Phase Basics

• Process mapping including (flowcharts, process steps, decision points)

• Data collection planning including (what to measure, how to measure, when to measure)

• Measurement concepts including (accuracy, precision, repeatability, reproducibility)

• Baseline establishment including (current performance, benchmarks, targets)

• Data organization including (data sheets, check sheets, data recording)

4. Process Improvement Tools

4.1 Seven Basic Quality Tools

• Check sheets including (data collection, frequency recording, pattern identification)

• Histograms including (distribution analysis, process capability, variation patterns)

• Pareto charts including (problem prioritization, focus areas, improvement opportunities)

• Cause-and-effect diagrams including (fishbone diagrams, brainstorming, root cause identification)

• Scatter diagrams including (correlation analysis, variable relationships, pattern recognition)

• Control charts including (process monitoring, variation detection, stability assessment)

• Stratification including (data segmentation, subgroup analysis, pattern investigation)

4.2 Process Analysis Tools

• Flowcharting including (process documentation, workflow analysis, improvement identification)

• Value stream mapping basics including (current state, waste identification, flow analysis)

• Process observation including (gemba walks, direct observation, fact gathering)

• Time studies including (cycle time, lead time, processing time)

• Bottleneck identification including (constraint analysis, capacity assessment, flow optimization)

5. Analyze Phase Fundamentals

5.1 Problem Analysis Techniques

• Root cause analysis basics including (five whys, cause-and-effect analysis, brainstorming)

• Data analysis techniques including (trend analysis, pattern recognition, comparison methods)

• Process capability concepts including (specification limits, process limits, capability indices)

• Variation analysis including (common cause, special cause, variation sources)

• Hypothesis formation including (problem theories, cause identification, testing approaches)

5.2 Statistical Analysis Basics

• Graph interpretation including (trend identification, pattern recognition, outlier detection)

• Basic hypothesis testing including (null hypothesis, alternative hypothesis, conclusions)

• Confidence intervals including (uncertainty, range estimates, statistical significance)

• Process performance including (yield, defects, process capability)

• Benchmarking including (best practices, performance comparison, target setting)

6. Improve Phase Fundamentals

6.1 Solution Development

• Brainstorming techniques including (idea generation, creative thinking, team participation)

• Solution evaluation including (feasibility assessment, impact analysis, resource requirements)

• Pilot testing including (small-scale implementation, data collection, results evaluation)

• Implementation planning including (action plans, timelines, responsibility assignment)

• Change management basics including (communication, training, resistance management)

6.2 Improvement Implementation

• Solution implementation including (step-by-step execution, monitoring, adjustment)

• Process standardization including (standard operating procedures, work instructions, training)

• Team participation including (active involvement, feedback, suggestion systems)

• Communication including (progress reporting, stakeholder updates, documentation)

• Continuous improvement including (ongoing enhancement, suggestion implementation, learning)

7. Control Phase Fundamentals

7.1 Process Monitoring

• Control chart basics including (control limits, plotting points, interpretation)

• Process stability including (statistical control, predictability, consistency)

• Monitoring systems including (data collection, measurement, tracking)

• Alert systems including (out-of-control signals, response procedures, corrective actions)

• Documentation including (records, procedures, training materials)

7.2 Sustainability Practices

• Standard work including (documented procedures, training, adherence)

• Process ownership including (responsibility, accountability, maintenance)

• Continuous monitoring including (ongoing measurement, trend analysis, improvement)

• Mistake-proofing including (error prevention, detection systems, simple solutions)

• Knowledge sharing including (lessons learned, best practices, training others)

8. Lean Fundamentals

8.1 Lean Principles

• Waste identification including (muda, mura, muri, eight wastes)

• Value identification including (customer value, value-added activities, non-value-added activities)

• Flow concepts including (continuous flow, bottlenecks, interruptions)

• Pull systems including (demand-driven, just-in-time, inventory reduction)

• Perfection pursuit including (continuous improvement, kaizen, incremental changes)

8.2 Lean Tools

• 5S methodology including (sort, set in order, shine, standardize, sustain)

• Visual management including (visual controls, visual displays, workplace organization)

• Standard work including (standardized procedures, work instructions, training)

• Error prevention including (poka-yoke, mistake-proofing, simple solutions)

• Kaizen including (continuous improvement, small changes, employee involvement)

9. Team Participation and Communication

9.1 Team Dynamics

• Team participation including (active involvement, contribution, collaboration)

• Communication skills including (listening, feedback, information sharing)

• Meeting participation including (preparation, contribution, follow-through)

• Conflict resolution including (problem-solving, compromise, collaboration)

• Leadership support including (following direction, initiative, responsibility)

9.2 Project Support

• Data collection including (accurate recording, timely submission, quality data)

• Process documentation including (procedure writing, diagram creation, record keeping)

• Implementation support including (change execution, training assistance, feedback provision)

• Monitoring assistance including (data tracking, observation, reporting)

• Continuous improvement including (suggestion systems, idea generation, problem identification)

10. Quality Management Systems

10.1 Quality Systems Overview

• ISO 9001 fundamentals including (quality management system, process approach, customer focus)

• Quality policy including (commitment, objectives, continuous improvement)

• Quality objectives including (measurable goals, performance indicators, targets)

• Document control including (procedures, work instructions, records)

• Management review including (performance evaluation, improvement planning, resource allocation)

10.2 Quality Assurance

• Quality planning including (quality objectives, process planning, resource allocation)

• Quality control including (inspection, testing, verification, validation)

• Quality improvement including (corrective action, preventive action, continuous improvement)

• Supplier quality including (supplier evaluation, quality requirements, monitoring)

• Customer satisfaction including (feedback collection, complaint handling, satisfaction measurement)

11. Problem-Solving Techniques

11.1 Systematic Problem Solving

• Problem identification including (problem definition, impact assessment, urgency evaluation)

• Problem analysis including (data collection, root cause analysis, fact-based investigation)

• Solution development including (alternative generation, evaluation criteria, selection process)

• Implementation planning including (action steps, timelines, resource requirements)

• Results verification including (effectiveness assessment, goal achievement, sustainability)

11.2 Creative Problem Solving

• Brainstorming including (idea generation, creative thinking, team participation)

• Mind mapping including (visual thinking, idea organization, relationship identification)

• Nominal group technique including (structured brainstorming, idea ranking, consensus building)

• Affinity diagrams including (idea grouping, pattern recognition, theme identification)

• Force field analysis including (driving forces, restraining forces, change planning)

12. HSE in Quality Operations

• Workplace safety including (hazard identification, safety procedures, personal protective equipment)

• Environmental awareness including (environmental impact, waste reduction, resource conservation)

• Risk awareness including (risk identification, risk assessment, risk mitigation)

• Regulatory compliance including (safety regulations, environmental requirements, quality standards)

• Emergency procedures including (emergency response, evacuation procedures, first aid)

13. Quality Assurance and Standards

• Quality standards including (industry standards, customer requirements, regulatory requirements)

• Quality auditing basics including (audit process, audit findings, corrective actions)

• Documentation systems including (quality manuals, procedures, work instructions)

• Record keeping including (quality records, traceability, document control)

• Continuous improvement including (audit results, corrective actions, preventive actions)

14. Case Studies & Group Discussions

• Regional improvement examples from Middle East operations including (manufacturing improvements, service enhancements, administrative efficiencies)

• Team-based improvement projects including (cross-functional initiatives, department improvements, process enhancements)

• Quality tool applications including (real-world examples, practical exercises, hands-on practice)

• Problem-solving scenarios including (workplace challenges, team solutions, implementation strategies)

• The importance of proper training in developing effective Yellow Belt practitioners and supporting organizational improvement