An Intensive 5-day Training Course

Structured Problem Solving
using Lean Sigma

INTRODUCTION TO THE COURSE

In today’s fast-paced and competitive environment, organisations must be equipped with effective problem-solving capabilities to stay ahead. This Structured Problem Solving Using Lean Sigma training course is designed to provide professionals with tools, techniques, and confidence to tackle complex challenges using a structured and data-centric approach.

Integrating the speed and efficiency of Lean with the accuracy of Six Sigma, this training course enables participants to systematically identify inefficiencies, uncover root causes, and implement sustainable improvements. Through practical case studies and simulations, attendees will learn how to apply the proven DMAIC (Define, Measure, Analyze, Improve, Control) methodology to real business scenarios, resulting in measurable impact and operational excellence.

This Structured Problem Solving using Lean Sigma training course will highlight:

  • A practical understanding of Lean and Six Sigma principles
  • Effective application of the DMAIC problem-solving framework
  • Process mapping, root cause analysis, and waste elimination
  • Hands-on exercises with real-life business case applications
  • Best practices for continuous improvement and performance measurement

COURSE DETAILS

Objectives Icon

OBJECTIVES

By the end of this Structured Problem Solving using Lean Sigma training course, participants will be able to:

  • Apply Lean Six Sigma techniques to solve business problems
  • Use data analysis tools to identify trends and pinpoint root causes
  • Reduce process variation and eliminate non-value-adding activities
  • Implement structured improvement initiatives that deliver measurable results
  • Promote a continuous improvement mindset across teams and departments
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TRAINING METHODOLOGY

This training course employs an interactive approach, combining lectures, group discussions, and practical exercises. Participants will engage in hands-on problem-solving scenarios, applying Lean Six Sigma tools to real-world challenges.

Delegates will be expected to work on a real problem within a company , analyse quality issues, describe and develop capabilities for continuous process improvement using key tools and techniques covered in class. Delegates will have the opportunity to develop their ability to analyse information, to use tools and techniques covered in class and to work under time pressure to make decision that can justify recommendations.

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ORGANISATIONAL IMPACT

Upon completion, organisations can expect to benefit from:

  • Reduced operational costs through process optimisation
  • Higher quality standards with fewer errors and defects
  • A unified approach to solving problems across departments
  • Faster decision-making based on clear data interpretation
  • Strengthened culture of accountability and performance
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PERSONAL IMPACT

Participants will gain:

  • Practical expertise in Lean Six Sigma problem-solving techniques
  • Enhanced analytical thinking and decision-making abilities
  • Greater confidence in leading process improvement projects
  • A systematic approach to tackling operational challenges
  • Recognition as a key contributor to organisational success
Target Audience Icon

WHO SHOULD ATTEND?

This KC Academy Structured Problem Solving Using Lean Sigma training course is suitable for a wide range of professionals but will greatly benefit:

  • Managers and Leaders involved in problem-solving.
  • Senior Managers seeking operational excellence Project Managers seeking Lean Six Sigma expertise.
  • Individuals responsible for continuous improvement initiatives.
  • Managers and Team Leaders
  • Cross functional Team Coordinators
  • Entrepreneurs
  • Professionals aspiring to lead sustainable initiatives.

DAILY AGENDA

Day 1: Lean Six Sigma Define Step
  • Quality culture and quality gurus
  • How good is good enough? Understand the core of six sigma
  • Lean principles
  • Overview of Lean Six Sigma DMAIC methodologies
  • Define step:
    • Group discussion: Identifying problem areas in your business.
    • Brainstorming and affinity diagram
    • Defining the problem
    • Stakeholder analysis and management
    • Project charter
    • Voice of Customer (VOC) and Cortical to Quality (CTQ’s)
    • Process map- SIPOC Diagram
    • Looking for COQ
    • Define: Story components
Day 2: Lean Six Sigma Measure step
  • Process performance measures
  • Lean operations and wastes identification.
  • Cost of poor quality
  • Process mapping and analysis
  • Data collection plan and measurement systems analysis
  • Operational definitions
  • Defect per millions opportunity and process capability
  • Measurement plan of Prioritised CTQ's and process performance
  • Measure’ flow

Practical exercise: measurement and process mapping in your business

Day 3: Lean Six Sigma Analyse step
  • Analysis of the process map
  • Establish causal relationships.
  • Cause and effect diagram
  • Determine root Cause(s) using Data.
  • Statistical analysis of data
  • Failure mode and effects analysis (FMEA)
  • Analyse Flow

Group activity: Conducting a root cause analysis for your problem

Day 4: Lean Six Sigma Improve step
  • Generate Ideas and develop solution Alternatives.
  • Consider lean techniques: Poke yoke, pull, 5s, Visual management, Kanban
  • Assess cost and benefits and risks
  • Solution scoring and selection
  • Determine solution effectiveness using PDCA (Plan-Do-Check-Act Deming cycle)
  • Design of experiments
  • FMEA for the new process
  • Improve Flow

Group project: Creating a Lean Six Sigma improvement plan for your organization/business/function

Day 5: Lean Six Sigma Control Step
  • Control plan
  • Process monitoring and control
  • Prepare DMAIC Project Documentation in Word
  • Finalise DMAIC Project Documentation
  • Lesson learnt.
  • Control Flow
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Certificate

On successful completion of this training course, KC ACademy Certificate will be awarded to the delegates.

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