Certified Lean Six Sigma Green Belt (2026)

Discover the cause and effect (Ishikawa) or fishbone diagram, a brainstorming tool in Six Sigma and lean manufacturing that helps map major causes for excess length of stay in hospitals.

Utilize the provided Excel template to build a cause and effect diagram, with machine, method, material, mother nature, measurement, and man, for quick brainstorming in green belt projects.

Lean Six Sigma is a team sport with roles like team leader, project sponsor, subject matter experts, and champion. Apply forming, storming, norming, and performing to guide cross-functional team development.

Explore the lean six sigma belt system—from white to yellow, green, black, and master black belt—outlining training scope, roles, and how belts empower project leadership.

Discover how Lean Six Sigma green belt training prepares you to lead and support projects, while emphasizing hands-on experience and validated black belt certification through real projects.

Understand how ddpm, defective parts per million, measures defects in high-volume processes and why percentages can mislead. Learn conversions like 0.1% equals 1000 ddpm and 0.01% equals 100 ppm.

Apply pareto analysis to prioritize problems by focusing on the significant few from customer feedback, rejects, and cost per piece, guiding targeted improvements.

Apply a practical Pareto analysis and diagram to forging defects using an Excel template, sorting by magnitude and computing cumulative percentages to identify top issues driving 80% of defects.

Apply the theory of constraints to identify the bottleneck and focus improvements on the constrained process to raise the overall production rate and reduce waste.

Learn how lean six sigma projects connect to organizational goals through ROI analysis, including payback period and net present value, with a focus on capital equipment.

Explore how inflation erodes purchasing power and drives the need for continuous improvement, Lean Six Sigma, and cost savings to sustain profits. See why ongoing improvement is essential amid inflation.

Download two project management templates—the project charter and the project work plan—to guide initiation and planning, with high-level descriptions, smart objectives, milestones, risks, and stakeholders.

Explore a collection of Lean Six Sigma blog posts that extend topics with downloadable pdfs on coefficient of variation, theory of constraints, design of experiments, and process capability analysis.

Define the problem clearly and quantify its effect on the organization and customers using qualitative and quantitative tools such as value stream mapping, Sipoc, and cost of quality.

Explore process modeling tools that graphically map workflows to identify bottlenecks and communicate improvements in lean six sigma projects, using flowcharts, sipoc diagrams, process flow diagrams, and value stream maps.

Flow charts provide a simple, widely recognized tool in the define phase to graphically depict processes using standardized symbols for inputs, outputs, decisions, and data flows.

Explore the sipoc diagram, a high level process map used early in lean six sigma projects to identify suppliers, inputs, process, outputs, and customers, with an Excel template for brainstorming.

Explore the process flow diagram, a structured map of production steps from raw materials to shipping, detailing machine specs, packaging, inputs, and key process characteristics.

Access an editable Excel process flow diagram template with four symbols (fabrication, move, store, inspect) and an example CNC machining workflow from raw forging to finished part, plus downloadable resources.

Apply value stream mapping to distinguish value added versus non-value added activities in lean manufacturing, identify essential and non-essential waste, and target transportation, rework, counting, and scheduling for elimination.

Learn value stream mapping in lean manufacturing through a transmission factory, tracing major steps from raw materials to finished goods and sales, with lead time and inventory insights.

For green belt Lean Six Sigma, examine non-value and value-added activities in value stream mapping, distinguish essential from non-essential waste, and consider value engineering via customer collaboration to reduce costs.

Learn to define problems by going to the gemba—the actual place where work happens, observe, talk to operators, and identify opportunities for continuous improvement through gemba walks.

Explore descriptive statistics to describe problems using central tendency measures and dispersion, including mean, median, mode, range, and standard deviation, with Excel demonstrations.

Explore how to calculate standard deviation in Excel, both by hand and with stdev.s, clarifying sample vs population and when to use n minus one vs n.

Enable the Excel Data Analysis Toolpak, then run descriptive statistics to quickly generate mean, median, standard deviation, variance, skewness, kurtosis, and other stats.

Explore rolled throughput yield, a lean metric that computes the defect-free output across a serial A1–A3 line, enabling upfront define-phase assessment and post-improve-phase comparison.

Analyze overall equipment effectiveness by multiplying availability, performance, and quality to form an oe benchmark, and identify six big losses such as unplanned downtime, slow running, and setup losses.

Use a downloadable oee excel template to calculate overall equipment effectiveness by entering runtime, planned production time, output, cycle time, and rejects, with built-in formulas for availability, efficiency, and quality.

Define teep as utilization times oe, noting planned downtime and its use for evaluating capital investments and equipment utilization with case: 64.1% utilization and 71.3% oe yield 45.7% teep.

Explore the cost of quality framework by Feigenbaum: four buckets—prevention, appraisal, internal, external. Learn how shifting costs upstream reduces external failures and saves money.

Understand the cost of quality framework by focusing on internal and external costs, highlighting prevention and appraisal investments to reduce the cost of poor quality (COPQ).

Learn to use an Excel cost of quality template that tracks prevention, appraisal, internal, and external costs, links to sales, and shows monthly and yearly trends.

Master break-even analysis as a Lean Six Sigma tool that links cost, revenue, and investment decisions. Use a fence painting example to determine units and justify upfront equipment costs.

Conclude the define phase by crafting concise problem statements with exact financial numbers and metrics, using Pareto analysis and graphics to prepare for the measure phase.

Identify key metrics and establish baselines in the Lean Six Sigma measure phase, then select measurement tools—such as ctq, capability analysis, observations—to quantify problem magnitude.

Explore SWOT analysis as a risk-aware lens for manufacturing quality management, analyzing internal strengths and weaknesses alongside external opportunities and threats to drive sustainable improvement.

Download this Microsoft Excel SWOT analysis template to identify strengths, weaknesses, internal and external opportunities and threats, with starter questions for team brainstorming and quick setup.

Explore benchmarking as a powerful Lean Six Sigma tool to study competitors, non-competitors, and standards, identify focus areas, collect and analyze data, adapt best practices, and drive continuous improvement.

Identify critical to quality characteristics and product characteristics driven by the voice of the customer, and connect them to process CTQs using design of experiments.

Assess process capability by comparing the specification range to the process range and applying Cp, Cpk, Pp, and Ppk to gauge fit.

Explore how process range relates to three sigma and the mean in a normal distribution, and calculate ppk and pp to compare process and specification ranges.

Calculate process capability indices using Excel to compare specification limits with sample data, compute mean and standard deviation, and interpret Pp, PpU, PpL, and Pk to assess centeredness.

Learn how to gather qualitative data through interviews and observations in lean six sigma projects, using open-ended questions and empathetic follow-ups to understand the informant's perspective without bias.

Learn to combine interviewing and observing to identify pain points, empathize with users, and translate insights into design improvements, such as lift-up coffee tables that improve posture.

Learn how stakeholders influence Lean Six Sigma projects and why identifying internal and external stakeholders, along with stakeholder analysis, is essential for successful project management.

Identify internal and external stakeholders and map them on a power interest matrix to tailor communication, engagement, and monitoring for Lean Six Sigma projects.

Use scatter plots to visualize the relationship between independent and dependent variables, interpret correlation, and distinguish correlation from causation, while preparing for regression analysis.

Explore building scatter plots in Excel to analyze correlations between the dependent flexor strength and two independent variables: mold temperature and material density, and interpret correlation values and matrices.

control charts extend run charts by adding statistical control limits to monitor process quality, using x-bar, r, and x-bar double bar with a2 for five-sample subgroups, cp and cpk.

Learn to build and interpret an x-bar and range control chart in excel, using time-based subgroups and five samples to monitor process stability with control and specification limits.

Explore measurement systems analysis (MSA) by examining how gauge readings reflect true value plus error, and identify bias, linearity, stability, repeatability, reproducibility, and resolution to judge gauge suitability.

Explore measurement systems analysis concepts, including gauge output, true part variation, and six error types (bias, linearity, stability, repeatability, reproducibility, resolution), with a focus on gage R&R and variance-based calculations.

Use an Excel template for gauge R&R studies, featuring a 10x3x3 design with ten parts, three appraisers, and three measurements per part to explore repeatability and reproducibility.

Conclude the measure phase of the dmaic process by identifying key metrics, establishing baselines linked to critical to quality characteristics and business goals, and noting capability analysis and control charts.

Explore the analyze phase by integrating measurements, observations, and data to uncover root causes, identify process drivers, and address sources of variation through practical tools.

Cultivate curiosity as a core problem-solving trait, awakening learning and driving continuous improvement by adopting a beginner's mindset, pursuing adjacent learning, and separating root causes from symptoms.

Revisit the cause and effect (Ishikawa) diagram as a cross-functional brainstorming tool for qualitative analysis, organizing ideas under the six M's before and after measurement.

Explore five whys, a popular brainstorming tool by Sakichi Toyoda, to uncover root causes beyond symptoms. Learn its three layers—occurrence, escapement, systemic—and its limits for complex failures.

Map the value stream from raw materials to shipping using value stream mapping and cycle-time analysis. Identify bottlenecks through value-added versus non-value-added hours and inventory.

Tie value stream mapping and analysis to takt time, defining the ideal cycle time as available production time divided by average demand, to achieve flow and minimize inventory waste.

The lecture analyzes the total cost of inventory, breaks it into part, fixed, and holding costs, and explains the economic order quantity and how smaller batch sizes reduce costs.

Learn the basics of simple linear regression using a scatter plot and a best-fitting line to relate air pressure to nail height, with Excel predictions and extrapolation cautions.

Explore qualitative analysis through observations and interviews to gain insights beyond numbers, while recognizing biases and confirming findings through independent verification in the Lean Six Sigma analyze phase.

Identify multiple potential root causes from analyze phase data, avoid oversimplification, and capture opportunities for improvement to fuel continuous Lean Six Sigma projects.

Identify and analyze root causes and sources of variation in the analyze phase using data, interviews, and statistical tools, then prioritize problems and repeat the cycle for continuous improvement.

Advance to the improve phase by implementing permanent corrective actions, prototyping solutions, and remeasuring to gauge improvement with five S, poka-yoke, and single-minute exchange of dies.

Apply the two by two impact matrix to prioritize improvement ideas by ease and impact. Classify actions into four quadrants to guide immediate fixes, backburner ideas, and major projects.

Learn how to set specific, measurable, achievable, relevant, and time-bound goals using the smart framework to align lean six sigma projects with business and customer needs.

Explore a downloadable smart goals Excel template that serves as a training tool for teams, guiding specific, measurable, relevant, and time bound goals aligned with business goals.

Master prototyping as a quick, cheap, and focused approach, using prototype, pilot, and production stages, to test ideas, validate design assumptions, and refine Lean Six Sigma project outcomes.

Apply the 5S system to create an organized, waste-free workspace that boosts efficiency, productivity, and morale. Learn the five steps: sort, straighten, shine, standardize, sustain—and how they sustain continuous improvement.

Use the 5S audit template in Excel to conduct periodic audits across sort, straighten, shine, standardize, and sustain, with applicable items, 1–5 scoring, and conditional formatting.

Explore maintenance concepts, including corrective, preventive, and predictive maintenance, and how technologies like thermal imaging, vibration analysis, oil analysis, and acoustic monitoring enable early fault detection.

Shift the mean within the specification range to center the process, improving PPK and reducing defects.

Explore cellular manufacturing as a lean alternative to batch production, using single piece flow and u-shaped layout to reduce inventory, motion, defects, and empower cross-trained workers with kanban and andon.

Explore SMED, a lean tool to reduce changeover time by converting internal setup steps to external ones, recording and sequencing the process to lower costs and boost profitability.

Discover poka yoke, or error proofing, and see how simple, inexpensive devices prevent defects from misorientation to incorrect connections, boosting lean manufacturing and Six Sigma quality.

Apply design for assembly to reduce components and reorientation while harmonizing parts for faster, reliable manufacturing. Use built-in fasteners, live hinges, and snap-to-fit features to cut assembly time and errors.

Blend physical changes with a shift in perception to implement Lean Six Sigma, demanding leadership involvement and concise, data-driven communication to align culture with improvement.

Test and refine corrective actions in the improve phase, implement permanent fixes, and pursue continuous improvement through small prototyping and iterative changes like poka-yoke and Kanban.

Explore downloadable essays and articles on five why analysis, process capability, sampling plans, Rockwell hardness testing, and soft skills for quality management.

Lock in the new methods from the dmaic control phase to prevent reverting, and use control charts, capability analysis, layered process auditing, and data collection checklists to sustain improvements.

Lock in improvements by writing a living document for the standard of the new method, and train to it with standardized work instructions, templates, sequences of operations, and visuals.

Develop and implement a process control plan that defines control methods, responsible parties, inspection frequency, and reaction plans, aligned with process design and statistical process control to lock in improvements.

Use Excel-based templates to launch your LPA process, record frequencies, positions, and questions, and manage non-conformances with an open/closed issues log and formal corrective actions.

Andon is a low-cost notification system using light stacks, sensors, and audible alarms to alert operators and maintenance when process variables go out of range.

Revisit control charts by reviewing how run charts and x bar and R charts establish upper and lower control limits, reflect current process variation, and require periodic verification after improvements.

Adopt checklists as simple, effective control tools, one of the seven quality tools, widely used in aviation, surgery, inspections, and manufacturing, including tooling and machine operators.

Identify and prepare for internal and external risks with contingency planning, using iATf 16949 as a framework to safeguard manufacturing processes and meet customer requirements through lean six sigma.

Develop contingency plans to ensure continuity of supply against equipment failure, supplier interruptions, natural disasters, cyber attacks, and labor shortages, with annual reviews and testing to protect the customer experience.

Conclude the control phase by ensuring the improved process stays in control, training staff on new work instructions, and deploying andon lights, control charts, and checklists for sustained results.

Reflect on continuous improvement and process improvement, summarize the skills, strategies, and tools learned, and remind learners of lifetime access, ongoing updates, and the Udemy certificate of completion.

Explore the bonus lecture, download resources listing all manufacturing and quality Udemy courses with coupon links, and learn about SPC, root cause analysis, and the eight D process.