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Lean Six Sigma 


     Lean SIX SIGMA 



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                                                                                                                                                                                     Six Sigma Green Belts/Black Belts

 What is Six Sigma? 


      Six Sigma is a rigorous and disciplined methodology that uses data and statistical analysis to measure and improve a company's operational performance by identifying and eliminating "defects" in manufacturing and service-related processes. Commonly defined as 3.4 defects per million opportunities, Six Sigma can be defined and understood at three distinct levels: metric, methodology and philosophy...

       Six Sigma is a customer focused, data driven methodology for achieving real break through success in business. Six Sigma is a comprehensive and flexible system and can be applied to reduce defects, improve designs and process efficiencies. To learn more about Six Sigma, please click here.


Why 3Sigma is not enough?

(Is 99.73% (= 3Sigma Performance Level) Really Good Enough?)

Even a three Sigma level company is not good enough, because a 3Sigma level performance means,

* 200,00 lost articles of mail per hour.
* No electricity for almost 7 hours, each month.
* 2 short or long landings at major airports, each day.
* 200,000 wrong drug prescriptions each year.
* Unsafe drinking water almost 15 minutes each day.
* 5000 wrong surgical operations per week.

 (The above information is based on a survey conducted in US)
            Now, can anyone afford to stop at 3Sigma level performance? If a company performs even at 3Sigma level, (that is 99.73% result fall with in the control limits) the above defects are possible. Because of the above cited huge loses, generally many companies go for Six Sigma Implementation Programs/Certification.

 Why you need to do Six Sigma?

          Six Sigma can cut waste and save money. Consider how much money could be saved by eliminating potential defects and the resulting scrap and warranty returns. Time and money may be wasted in corrective actions and delays. Also consider the image those results from product failures for the customer. In order to determine the waste, you need to understand what adds value to your product and what does not.


        One way to know how good you are doing is to compare your operation to similar ones elsewhere, as a benchmark. If there are similar operations in your organization, then bench marking will be easier.


Lean Six Sigma Costs and Savings

One can't expect to significantly reduce costs and increase sales using Six Sigma without investing in training, organizational infrastructure and culture evolution. Sure you can reduce costs and increase sales in a localized area of a business using the Six Sigma quality methodology. For Example,

* Motorola adopted Six Sigma in1987. In 1988, Motorola won its first Baldridge Award.
"Companies of all types and sizes are in the midst of a quality revolution. GE saved $12 billion over five years and added $1 to its earnings per share. Honeywell (AlliedSignal) recorded more than $800 million in savings."

"GE produces annual benefits of over $2.5 billion across the organization from Six Sigma."

"Motorola reduced manufacturing costs by $1.4 billion from 1987-1994."

"Lean Six Sigma reportedly saved Motorola $15 billion over the last 11 years."

 Who  should attend?

            CEOs, Presidents,  Project Managers, Team leaders/Members, Field Staff Members, Project Engineers, Design Engineers, Project Leaders and Administrators, Industrial Engineers, Program Managers, Manufacturing Engineers, Project Coordinators, Operating Managers, Functional Managers, Information Technology Professionals, Software Developers, Quality & Testing Engineers, Sales & Marketing professionals, Civil/Mechanical/Electrical engineers, Procurement specialists, Event mangers, R&D Managers, others involved directly or indirectly with Project Management, Quality assurance managers, BPO team leaders, and Executive leadership from Finance, Training, Communications, Human Resources and Quality who are interested in gaining a better understanding of manufacturing processes and reducing process variability in order to improve business success. This includes:

* Individuals who desire to enhance their professional development with the skills necessary to support Six Sigma projects.

* Employees of companies that have deployed Six Sigma, who work with Black Belts, or who lead their own improvement projects. Companies that want to expand training across a wide range of employees to reduce costs and improve performance

Course Structure (Online):

        This Six Sigma Green Belt course is a PMI approved web-based self-study course with access to the participants to the online resources for 3-6 months including the green belt project completion time.  The course is supplied with an end of the course evaluation test of what was learnt and the participants will be supported with Excel templates where ever required.


        All online participants who are PMPs will earn 40 PDUs Certificate towards their CCR once they have completed 40 hours of online study through this PMI approved PDU course.  Sample PDUs Certificate. Click Here


         All online participants can also download a full Green Belt editable project template for their use.


Course Structure (Classroom):

        This Six Sigma Green Belt course is a PMI approved Classroom study.


       All classroom participants who are PMPs will earn 40 PDUs Certificate towards their CCR on the 4'th day through this PMI approved PDU course.


         All classroom participants will be given a CD of full Green Belt editable project template for their use. The CD contains DMAIC stages, simple explanations, some situational case studies, useful templates and Statistics Software. This software useful to calculate sigma levels and to draw Excel charts.

·         Control Chart

·         Creating Control Charts Using Microsoft Excel

·         Editable Project Charter

·         Editable Sipoc Diagram

·         Project selection

·         QI-Statistics Software

·         Sample Size Calculator

·         Sigma Conversion Table

·         Six Sigma Sample Questions

·         Six Sigma Sample Project Report


·         16, 17, 18, 19  May' 09



Course fee for Lean Six Sigma Green Belt Certification - CLASS ROOM:


      * Green Belt Certificate Only - Special offer fee Rs. 15,000 + 10.3% service tax only (for general professionals)
      * Green Belt Certificate + 40 PDUs Certificate -
Rs. 19,000 + 10.3% service tax only (optional item for PMPs only)

Course fee for online participants:

      * Green Belt Certificate Only - Special offer fee US $ 340 only (for general professionals)
      * Green Belt Certificate + 40 PDUs Certificate -
US $ 400 only (optional item for PMPs only)

Lean SIX SIGMA Green Belt Sample Certificate. Click Here

Sample PDUs Certificate. Click Here



PDUs Offered:


    Earn 40 PDUs (PMI Approved) - Click here to see PMI Approval.


Course Completion Exam:

   A 100 questions based test to measure the knowledge gained by the participants and to demonstrate the added confidence level out of this course.


GB Project Details:

      GB Projects:


        Please note that the projects for improvement can be from your own company (or) any other company. The projects can address the entire company are small portion (or) part (or) division (or) a small process of a business unit with in the company. The candidates can also suggest project titles from their company for the faculty / instructors / suggestions (or) they can choose any one of the projects available at IIPM. IIPM will facilitate the collection of data and extend support staff services for the project period.  

Lean Six Sigma Projects Guided by IIPM:

1. Case management in Microsoft, Sutherland – A Case study - BPO Industry.

2. Reducing Turn Around Time (TAT) of Production Support Request in Cambridge Solution – A Case study - Manufacturing


3. Reduction of OLA Deviation in CVS processing in SIFY – A Case study - Software Industry.

4. Reduction in Manufacturing of Flanges Production Turn Around Time (TAT)-A Case study-Construction / Fabrication Industry.


Some example projects are below.  


Project 1)  Registration process improvement.

Project 2)  Defects and improvements in Training.

Project 3)  Defects and improvement in online training .

Project 4)  customer Call registration Improvement.

Project 5)  Training course-ware quality improvement.

Project 6)  Admin and maintenance expenses improvement.   



The participants can identify projects in their own organization and implement the DMAIC methodology and show significant improvement in organization. The Students shall review the projects with IIPM on monthly basis. Any questions clarifications can be discussed during the review. Sample project also available for all Online/Classroom registered participants.


Lean SIX SIGMA Green Belt Certificate:


       This Green Belt certificate will be awarded to all those who have completed the course by passing a test at the end of the course. Please note those sample/model practice questions are available for participants. However Green Belt project completion certificate will be awarded if one has finished / implemented Six Sigma Projects in his/her organization and shows significant improvement in the process chosen for improvement.


Lean SIX SIGMA Green Belt Sample Certificate. Click Here


Sample PDUs Certificate. Click Here


This 40 hours PDU certificate will be awarded those who have finished 40 hours of study from this course. 



      Useable, practical templates and tools are downloadable in our Six Sigma course. These templates are editable and can be modified to suit your company’s requirements.





   Click Here to download the Classroom Course Contents



1. Introduction

• Introduction to Six Sigma
• History of Six Sigma
• How to work Six Sigma
• Goals and Objectives
• Benefits of Six Sigma
• What is Quality
• Gaps in Service
• Achieving Six Sigma quality

• Voice Of Customer

2. Basic Statistics

• Introduction
• Mean, Median, Mode
• Variance, SD
• Process Capability

• Voice of customer

• Six Sigma Data Type's

• Normal Distribution

• Organizational Structure and Roles

• COPQ (Cost Of Poor Quality)

3. Six Sigma Methodologies

• Six Sigma metrics
• Yield Computations
• Hidden Factory
• How to calculate Sigma level

4. DEFINE Stage

• Introduction to DEFINE Phase
• Objectives
• Project Charter
• Introduction SIPOC
• Create SIPOC
• Sample SIPOC

• Flow Chart

• Process map

• Top level Process definition

• KANO’s model

• Quality Function Deployment

• Affinity Diagram

5. MEASURE Stage

• Introduction to MEASURE Phase
• Objectives
• Why MEASURE phase needed

• Key Performance Indicators (KPI)
• Metric definition
• CTS,CTQ,CTP Explained
• Measurement System Analysis

• Precision versus Accuracy
• Sampling methods
• Process Capability

• Value-added Non-Value-added activities

6. ANALYZE Stage

• Introduction to ANALYZE Phase
• Objectives

• Failure Modes and Effects Analysis
• Value Stream Analysis
• Analyzing Sources of Variation

• Exploratory Data Analysis (EDA)

• Data Mining

• Check sheet
• Run Chart
• Pareto Analysis
• Scatter diagram
• Cause and effect diagram
• Control charts

• Box-Plot-Components

• Hypothesis Testing

• Risk

7. IMPROVE Stage

• Introduction to IMPROVE Phase
• Objectives
• Defining the New Processes

• Lateral Thinking
• Brainstorming

• Benchmarking

• Five-S

• Mistake Proofing

• Design of Experiments (DOE)
• Implementation and Verification

8. CONTROL Stage

• Introduction about CONTROL Phase
• Objectives
• Standardize on the New Methods
• Measure Bottom line Impact
• Standard Operating Procedure
• Process audit system


9. Control Charts

• I-MR charts (Moving range, Individuals)

• X bar R charts

• X bar S charts
• Np Chart
• P Chart
• C Chart
• U Chart


10. Introduction to DMADV

• Introduction
• Design for Six Sigma

• Lean Six Sigma

11. Conclusion

• Purpose and guidelines of DMAIC
• Checklist for DMAIC
• Do’s and Don’ts to DMAIC

12. Class Room Exercises

13. Case Study

14. Final Six Sigma Exam – Open book / Group Test

15. Six Sigma CD Demo

16. Certificate Distribution

17. General Q&A

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