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Lean Six Sigma with AI: Find, Prove, Fix

Learn DMAIC, root cause analysis and A3 with Excel tools, plus how to triage AI ideas. By a Master Black Belt.

Created byChris Parker

Last updated 11/2026

English

What you'll learn

Explain the DMAIC method and where each Lean Six Sigma tool fits
Define a problem with a clear problem statement, SIPOC and customer requirements
Map a process, spot the eight wastes and separate failure demand from value
Plan data collection and read histograms, run charts, scatter plots and Pareto charts
Find root causes with a fishbone and the five whys, and test them with data

Course content

8 sections • 75 lectures • 1h 46m total length

Welcome: what this course will do for you2:02
What is Lean Six Sigma?1:28
Where did it come from?1:44
Who uses it and who does what1:36
Why Lean and Six Sigma, and the DMAIC method1:55
The voice of the customer1:59
Why customers hate variation1:23
From gut feel to facts1:18
Choose your problem1:37

Where we are and what this module does0:49
Why map the process1:11
How to create a detailed process map1:12
The levels of process map and the symbols1:15
Exercise: map your process0:42
Spaghetti diagrams0:55
Value add, value exception and non value add1:32
The eight wastes and the waste in services1:40
Failure demand: the biggest waste in services2:01
Exercise: find the waste0:50
Summary, quiz and before Module 41:56

Where we are and what this module does0:44
Why we collect data and the plan1:20
Gathering, sampling and can you trust the measurement1:21
Data collection plans and forms, and your exercise1:50
Basic statistics: average and variation2:07
Histograms and the dice game1:27
Patterns of distribution1:10
Run charts, pie charts and scatter plots1:53
The Pareto chart1:51
Exercise: build your Pareto0:51
Summary, quiz and before Module 52:44

Where we are and what this module does1:12
Generating ideas and error proofing1:14
Choosing: the Pugh matrix1:12
Managing risk: stop, look, listen, think0:45
Implementation plans0:45
Your improvement exercise, with one good answer2:49
Control: why gains fade, and the control plan1:28
Real shift or normal variation? The control chart1:17
The A30:46
Your A3 exercise0:39
Your four week plan0:46
Summary, quiz and before Module 72:21

Where we are and what this module does1:32
Why most AI projects disappoint1:02
Do not automate failure demand1:00
Where AI fits in DMAIC0:50
Analyse with a lean lens0:56
The five verdicts, and is it really a job for an agent?2:11
A worked example: a home insurance claim1:04
Your triage exercise0:52
Score the use case: value, feasibility and risk1:01
The one page business case1:43
Prove it: pilots and two real stories1:37
Enterprise thinking: build once, use many times1:05
Summary, quiz and close2:55

Requirements

No Lean Six Sigma or statistics background needed
Excel (any recent version) for the exercises; the tools are plain Excel, no macros

Description

This course contains the use of artificial intelligence.

Most improvement projects fail for the same reason: the team jumps to a fix before it has found the cause. This course teaches the method that stops that happening, in plain language, with tools you can use on Monday morning.

I am a Master Black Belt with 22 years in improvement, including UK financial services and contact centres. In this course I take you through the whole DMAIC method, Define, Measure, Analyse, Improve and Control, using the same approach I use with real teams. Every module ends with a short knowledge check, and every module has exercises where you work on your own problem.

What you will do

• Define a problem so everyone agrees what it is, using a problem statement, SIPOC and customer requirements.

• Map the process, find the eight wastes, and learn why some work is failure demand that should not exist at all.

• Collect good data, read variation, and use histograms, run charts, scatter plots and Pareto charts without needing advanced statistics.

• Find root causes with a fishbone and the five whys, and check them with data before anyone acts.

• Choose a solution with a Pugh matrix, manage the risk of change, run a trial, and make the gain last with a control plan and a control chart.

• Put the whole project on one page with an A3.

A module on AI, from a process point of view

Most AI projects disappoint because the work around the tool was never redesigned. Module 7 shows you how to triage every AI idea with five verdicts: remove, simplify, automate, assist or agent. You will score use cases for value, feasibility and risk, build a one-page business case, and design a pilot that proves the result. You do not need any technical knowledge of AI.

What is included

• Seven modules and a short bonus lecture

• Excel tools with worked examples and blank versions, for personal use

• Pause-the-video exercises with a course workbook

• Knowledge checkers at the end of every module

Real examples

You will see worked examples from contact centres, insurance claims, order handling and field operations. Company details are generalised, and any data shown as an example is fictional and labelled as such.

How the course is made (AI disclosure)

The narration is produced with an AI voice clone of my own voice, so the course sounds consistent throughout. I wrote the content and stories, and I reviewed every lecture. The slides were designed with AI assistance. I am telling you this because I think you should know.

Certificate

You receive Udemy's certificate of completion when you finish the course. It is a practical foundation in the method, built on real examples.

If you want to stop guessing and start finding causes, this course is for you.

Who this course is for:

Team members, managers and improvement staff who want a practical method for fixing problems at work
Operations, quality, compliance, customer service and continuous improvement staff, including in regulated businesses

Lean Six Sigma with AI: Find, Prove, Fix

What you'll learn

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Course content

Module 1: Start with the problem9 lectures • 15min

Module 2: Define9 lectures • 14min

Module 3: Map the process and find the waste11 lectures • 14min

Module 4: Measure11 lectures • 17min

Module 5: Analyse9 lectures • 11min

Module 6: Improve and control12 lectures • 15min

Module 7: AI in Lean Six Sigma13 lectures • 18min

Closing1 lecture • 2min

Requirements

Description

Who this course is for: