Home / Non-Accredited / Project Management, Agile & Process Improvement / Lean Process and Six Sigma Training (2 days)
Quick Look Course Summary:Lean Process and Six Sigma Training (2 days)
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Length: 2 day(s)
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Price (at your venue): 1 Person R 10,326 EX VAT 3 Person R 7,594 EX VAT 10 Person R 5,537 EX VAT
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Certification Type:Non-Accredited
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Locations & Venues: Off-site or in-house. We train in all major city centres throughout South Africa.
Lean Process And Six Sigma – self-paced online, 6 months’ access: R1,250 per learner (ex VAT); teams of 10 or more pay less.
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Lean Process and Six Sigma Training (2 days)
Staff who can spot waste, measure a problem properly and contribute to improvement projects using proven Lean and Six Sigma tools.
Most organisations know their processes carry waste – rework, waiting, duplicated approvals, stock nobody needs – but improvement efforts stall because staff see process improvement as a specialist's job. This practical two-day lean six sigma training shows ordinary teams that the core methods are simple, structured and usable at every level, from the production line to the finance office.
Day one covers Lean: where it came from in the Toyota Production System, the five lean principles, what customers actually value, the forms of waste (muda, mura and muri), variation, complexity and continuous improvement. Day two covers Six Sigma: the DMAIC and DMADV roadmaps, choosing and scoping an improvement project, and the everyday tools – value stream mapping, Pareto charts, cause-and-effect diagrams, the 5 Whys, histograms and mistake-proofing.
Delegates apply each tool to processes from their own workplace. They leave able to take part in Lean Six Sigma projects as informed contributors, spot improvement opportunities in their own area and support the Green and Black Belts who lead larger projects.
Why this course
For your organisation
- Staff who see waste and raise improvement ideas
- Fewer errors, less rework and shorter turnaround times
- A common improvement language across departments
- Team members ready to contribute to Lean Six Sigma projects
- Decisions based on data rather than opinion
For your delegates
- A clear picture of how Lean and Six Sigma fit together
- Hands-on practice with the most useful improvement tools
- A list of improvement opportunities from your own work area
- Confidence to contribute to improvement projects
What delegates will be able to do
- Explain the principles of Lean and Six Sigma and how they complement each other
- Identify value from the customer's point of view using the Kano model
- Recognise the eight wastes, unevenness and overburden in a process
- Distinguish common-cause from special-cause variation and avoid tampering with a stable process
- Map a value stream and find where flow breaks down
- Follow the DMAIC steps to work through an improvement problem
- Use Pareto charts, cause-and-effect diagrams, the 5 Whys and histograms to find root causes
- Select and scope a realistic improvement project for your area
Who should attend
Supervisors, team leaders, process owners, quality and operations staff, administrators and managers in manufacturing, logistics, financial services, healthcare and the public sector. It suits anyone who will take part in improvement projects or wants a solid introduction before committing to belt certification. No statistics background is needed.
Course outline
Day 1 – Lean thinking and the improvement concepts
Lean, Six Sigma and the Toyota Production System
- What Lean is, what Six Sigma is, and why they are combined
- How Lean grew out of the Toyota Production System
- The Toyota Way: long-term thinking, sound processes, respect for people and constant problem solving
- The TPS house: just-in-time, jidoka and the kaizen foundation
The five lean principles
- Defining value through the customer's eyes
- Mapping the value stream
- Creating flow and letting customer demand pull the work
- Pursuing perfection through small, continuous steps
Value and waste
- The Kano model: basic needs, performance factors and delighters
- Muda: the eight wastes, from overproduction to unused talent
- Mura and muri: unevenness and overburden
- Spotting waste in office and service processes, not only in factories
Variation and complexity
- Common-cause and special-cause variation
- Why tampering with a stable process makes it worse
- Where complexity comes from and how to simplify
Continuous improvement in practice
- The PDSA cycle for small, tested improvements
- Going to the gemba: seeing the work where it happens
- Kaizen events and daily improvement habits
- A roadmap for introducing Lean in your area
Day 2 – Six Sigma methods and tools
Six Sigma principles and roles
- What 'six sigma' means: defects, variation and process capability in plain terms
- Focusing on the customer and finding the root cause
- Yellow, Green and Black Belts, champions and process owners
DMAIC and DMADV
- Define: the problem statement, scope and project charter
- Measure: collecting baseline data
- Analyse: finding and verifying root causes
- Improve and Control: testing solutions and holding the gains
- DMADV for designing a new process
Selecting and running an improvement project
- Choosing and scoping projects that matter
- Linking improvement to cost, quality and customer loyalty
- Leading change and getting buy-in from the team
The improvement toolkit
- Value stream mapping
- Pareto charts and histograms
- Cause-and-effect (fishbone) diagrams and the 5 Whys
- Brainstorming, benchmarking and gemba walks
- Mistake-proofing (poka-yoke) and 5S
Applying it at work
- Workshop: a mini-DMAIC on a process from your workplace
- Presenting findings and quick wins
- Personal action plan and evaluation
How it is delivered
Two days, 08:30-16:00. In person at your offices anywhere in South Africa, at a BOTI venue, or live online. One delegate or a group of up to 20; exercises use processes from your own sector on request. Workbook, case studies and tool templates included. We deliver it at your offices in Johannesburg, Pretoria, Durban, Cape Town and anywhere else in South Africa, at a BOTI venue in Johannesburg, or live online for teams in different places.
What our clients say
“The facilitator was excellent and took time to ensure that the employee understood the content and was able to apply the learning in order to develop the portfolio of evidence.”
“The training was well received and we were impressed by the knowledge of the facilitators and the quality of overall training.”
“The training went well, and judging by the feedback from the evaluation forms we received, we were impressed by the knowledge of the facilitator and the quality of training overall.”
Frequently asked questions
Can you run this course at our offices?
Yes. Most groups are trained at the client's premises anywhere in South Africa. We can also host it at a BOTI venue or deliver it live online.
How many people can attend?
From one delegate to groups of about 20. The price per delegate drops as the group grows – see the price table, or ask us for a quote.
Is it accredited?
No – it is a non-accredited short course and delegates receive a BOTI certificate of attendance.
Is this a Yellow Belt certification?
No. It is a practical two-day introduction to Lean and Six Sigma. If your staff need a belt certificate, see our Lean Six Sigma Yellow, Green and Black Belt courses.
Does it work outside manufacturing?
Yes. Examples cover offices, call centres, finance, healthcare and government services as well as production lines, and private groups can work on their own processes.
Do delegates need maths or statistics?
No. The tools are taught visually and practically; the statistical depth comes in the Green and Black Belt courses.
Related courses
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Monday to Friday, 08:00–17:00. After hours, we reply on the next working day – or call 011 882 8853.