Duration: 4 hours

Learning Goals:

• Understand what Continuous Improvement is and why it matters

• Introduction to Lean Manufacturing, Six Sigma, and Lean Six Sigma methodologies

• See real-world applications across industries

Topics Covered:

• Evolution of Continuous Improvement and its impact on industries

• Lean Manufacturing vs Six Sigma vs Lean Six Sigma

• Introduction to your instructor-led classroom project

Duration: 8 hours

Learning Goals:

• Learn how to define a business problem effectively

• Capture customer expectations and project scope

• Assignment of individual student project & Launch your own Lean Six Sigma project with clear direction

Topics Covered:

• Project Charter, SIPOC, CTQ Trees

• Voice of Customer (VoC)

• Project Plan

Live Demonstration: Instructor walks through Define Phase deliverables using a real classroom project — showcasing how to frame problems, engage stakeholders, and define scope.

Knowledge Check:

• Mini case-based quiz

• Students apply learned concepts and produce Define Phase deliverables for their individual project.

Duration: 10 hours

Learning Goals:

• Map current-state processes accurately

• Plan and execute data collection

• Establish baseline metrics for improvement

Topics Covered:

Process Mapping (beginner to advanced):

• Process Mapping Basics - Standards (BPMN), Symbols. Rules etc.,

• Process Mapping Methods - (Functional Process maps, Value Stream Mapping, Spaghetti maps etc.,

• Process Mapping Tools - Lucidchart, Visio

Data Collection:

• Data Types, Sampling, and Collection Planning

• Measurement System Analysis (MSA)

Live Demonstration: Instructor demonstrates advanced process mapping using classroom project. Data planning and collection strategy is explained with live examples.

Knowledge Check:

• Short scenario-based quiz + sample process map review

• Students apply learned concepts and produce Measure Phase deliverables for their assigned project.

Duration: 20 hours

Learning Goals:

• Uncover root causes behind process inefficiencies or defects

• Use statistical tools to perform data analysis

• Prioritize what to fix and why

Topics Covered:

Process Analysis:

• Value Analysis (Value add vs Waste)

• Bottleneck Analysis (Theory of Constraints)

• Process Automation Analysis

Defect Analysis:

• Root Cause Analysis (5 Whys, Fishbone Diagram)

Data Analysis:

• Descriptive & Inferential Statistics

• Hypothesis Testing using Minitab

• Process Capability, Control Charts

Defect Buckets and Quick Win Identification

Live Demonstration: Instructor walkthrough of Analyze Phase deliverables on a classroom project — including root cause analysis, Minitab demonstrations, and interpretation of outputs.

Knowledge Check:

• Assessment covering Process Analysis and Data Analysis concepts.

• Students apply learned knowledge to produce Measure Phase deliverables for their assigned projects.

Duration: 10 hours

Learning Goals:

• Design solutions that address root causes effectively

• Use structured frameworks to prioritize and implement improvements

• Build a business case and manage change

Topics Covered:

• Solution Generation & Prioritization (e.g., Pugh Matrix)

• Future-State Process Design

• Cost-Benefit Analysis & Business Case

• Change Management Planning

• Automation, Error-Proofing & Standardization Methods

Live Demonstration: Instructor walks through how to identify and prioritize solutions using the classroom project. Techniques for visualizing future state and building change plans are showcased.

Knowledge Check:

• Enhanced process efficiency and minimized waste through targeted improvements.

• Standardized workflows implemented to streamline system operations.

• Conducted detailed data analysis and corrective actions to optimize project outcomes.

• Redesigned training module to boost learner engagement and retention.

• Increased report accuracy by thorough cross-verification of data sources.

• Students learn how to build and submit their own Improvement Plan, Future State process map, and business case documentation.

Duration: 6–8 hours

Learning Goals:

• Sustain your improvements through controls and ownership

• Prepare for project closure and handoff

• Reflect on lessons learned and showcase impact

Topics Covered:

• Control Plan Development

• Control Charts & Dashboards

• Lessons Learned & Knowledge Transfer

• Project Handover Documentation

• Finalizing and presenting both classroom and personal projects

Live Demonstration: Instructor demonstrates how to build a Control Plan and documentation package using the classroom project — including how to wrap up a CI project professionally.

Knowledge Check:

• Control strategy scenario quiz

• Students apply learned concepts and produce Control Phase deliverables for their assigned project.

Duration: 8 hours

Learning Goals:

• Learn how to perform statistical analysis in Minitab from scratch

• Gain confidence using Minitab for CI interviews and real-world roles

Topics Covered:

• Importing data & setting up projects

• Graphical tools: Histograms, Box Plots, Scatter Plots

• Descriptive & Inferential Statistics

• Hypothesis Testing

• Control Charts & Capability Analysis

• Live walkthroughs using real data sets

Hands-On: Students practice running complete analysis in Minitab with guidance from instructor-led demos.

Duration: 4 hours

Learning Goals:

• Understand how CI projects align with project management practices

• Learn how to manage timelines, risks, and communication in improvement projects

Topics Covered:

• Key phases of a project lifecycle

• Creating Work Breakdown Structures (WBS)

• Project timelines, milestones, and Gantt charts

• Risk assessment and mitigation

• Reporting and stakeholder communication

Application: Students align their own LSS project to a simple project plan using PM tools.

Duration: 4 hours

Learning Goals:

• Learn how to implement solutions that stick

• Understand how to deal with resistance and gain buy-in

Topics Covered:

• Change Management frameworks (ADKAR, Lewin’s Model)

• Stakeholder analysis & communication planning

• Building a change adoption roadmap

• Reinforcement & sustainment strategies

Application: Students create a mini change plan for their LSS project implementation phase.

Duration: 4 hours

Learning Goals:

• Bridge the gap between technical improvements and business needs

• Learn how to gather and translate requirements in CI settings

Topics Covered:

• Business analysis role in improvement projects

• Stakeholder requirement gathering

• User stories & process documentation

• Aligning project outcomes with business value

Application: Students build a basic business requirement document (BRD) related to their LSS project.