Every business needs to be profitable and productive to succeed, which requires pursuing consistent improvements in process, quality, and overall efficiency. Some of the world’s most prominent enterprises implement Six Sigma Green Belt projects to achieve these outcomes.
Are you looking to work as a Six Sigma expert for these organizations and contribute to successful Green Belt projects? If yes, this article is for you.
Keep reading as we explore the basics and examples of green belt projects and discuss how to develop one. We’ll sign off this article with our recommendation of an industry-recognized Six Sigma course that offers a fantastic start in this field.
What is a Green Belt project?
A Green Belt project is an improvement project undertaken to solve business problems without known solutions. It is a step-by-step approach for managing process quality and reducing costs. The project aims to find the root cause of the problem and devise a solution for it. Thus, a Green Belt project dives deep into every aspect of the process to reach the origin of the problem.
Read More: Understanding Six Sigma Belt Levels: A Comprehensive Guide
Top Examples of Green Belt Projects
Green Belt projects can be applied to various scenarios across an equally wide variety of industries. Let’s look at some examples of these projects to understand their scope and applications.
1. Dimensional deviation in sheet metal manufacturing
Suppose there have been repetitive customer complaints about metal sheets with a greater thickness than the recommended value. The project will find the root cause of this dimensional variation. The analysis includes observing the raw material and process parameters. The solution will involve changing process parameters and improving inspection techniques to identify the defective parts before shipping.
2. Low traffic to the company’s Facebook page
If a brand observes low traffic to the company’s Facebook page, it can use Green Belt project principles to identify the solution. The analysis requires obtaining data regarding audience demographics, preference for video or text-based posts, and the most viewed time slots. A/B testing can be used to post the same content with only text, with or without a video, picture, external links, or a variation of hashtags. The resolution is to tweak the posts with popular hashtags and optimize the quality of text and scheduling of posts.
3. Incorrect invoicing in a grocery retail shop
Suppose there have been multiple instances where the invoices in a retail shop had the wrong quantities, weights, or prices, resulting in the repetitive work of recalling and issuing a fresh invoice. The problem to solve here is to provide a system where the product selection, updating its quantity, and calculating the price are automated. The invoicing system is evaluated for its drawbacks. As a solution, the invoicing software may be updated to include bar codes, an easy updating method for prices, and customization for cancellation and manual entry if required.
4. Dispensing of expired medicines to patients in hospital
A hospital is facing multiple complaints about patients who have received expired medicines from the hospital pharmacy. A Green Belt project will include observing the process of communicating prescriptions to the pharmacy, tracking the medicine collection, and evaluating the system for flagging expired medication. As a solution, the pharmacy can use a better system that sends out regular alerts via emails about the medicines expiring soon and additional quality checks where the expiration date is automatically recorded via barcode scanning and checked before the medicine is dispatched.
5. Crashing and bugs in software
A gaming app has received several user complaints about the software crashing in the middle of a gaming session. The problem is checking for bugs and how they went undetected before the release. The analysis includes examining each step of the game development and noting the testing processes. The issue may be resolved by recommending a change in the checklist used for testing and implementing additional beta testing on diverse systems before a further update to the game.
Features of Six Sigma Green Belt Projects
Every Six Sigma Green Belt project is unique in the problem it solves. However, all of them possess certain key features. Here’s a list for your consideration.
- These projects lead to a reduction in waste and increased output
- They identify and correct the quality issues
- They improve existing processes and optimize the implemented processes
- The projects facilitate overall quality management
- The approach is data-driven, result-oriented, and structured based on DMAIC principles
- The projects are manageable and designed not to overwhelm the system or the team
- They require efficient cross-functionality and collaboration for a streamlined resolution
- They use a customer-centric approach to deliver continuous improvement
Also Read: How Lean Six Sigma Belts Can Increase Your Value and Salary?
How to Choose a DMAIC Green Belt Project
DMAIC stands for Define, Measure, Analyze, Implement, and Control. It is a systematic approach to addressing process issues, resolving them, and assessing the implementation of process improvement. This methodology is applied to Green Belt projects to facilitate a streamlined process and quality enhancement.
However, as they say, well begun is half done. So, choosing the right Green Belt project that fits into the DMAIC steps is the first step toward completing them. Let us look at the criteria for selecting a DMAIC Green Belt project.
- You must be able to complete the project in around three months
- The project’s scope must be moderate and address a critical problem in the enterprise
- The problem must be simple enough to be solved in a short time frame or a problem with an obvious solution
- The team must be small and have the right skills and creative thinking to tackle each aspect of the project and arrive at an ideal solution
- You must talk to your peers and ask one of them to be your sponsor. They will guide and assist you in navigating the organizational structure and accessing the required information.
- A good starting point is to examine the most common customer complaints and narrow down the main process issue that led to them
- You should gain control of the operation that you select to improve so that you can implement and monitor the changes with the help of your sponsor
- The project must be a medium-sized exercise that solves a critical problem with tangible results. An abstract or multi-faceted issue can lead to confusion and zero results, leaving the project in limbo.
How to Develop Lean Six Sigma Green Belt Projects?
Now that we have adequately described what Green Belt projects are let’s go through the chief steps of developing these projects:
- Identify the problem
Source out the customer complaints or quality issues and assess them for common denominators. Narrow down the operation that is causing most of them. Identify the process and the problem with the process. Define the problem statement and the scope of your work. Communicate it to your team.
- Conduct a review of the problem
Taking a problem at face value and providing a quick solution is like applying a Band-Aid on a fracture. To solve the problem, you must first know the background of the process, the details of the process parameters, and the inspection techniques or quality checks. Talk to the concerned people and get their viewpoint. Explore resources to learn about the process and connect with your peers to see if anybody else has encountered a similar problem.
- Analyze the problem
This step is where you will apply your Lean Six Sigma skills. Collect historical data and use statistical analysis to gain deeper insights. Observe the process firsthand on the shop floor or working area. Collaborate with the in-house and third-party laboratories and communicate with the other departments for information on transactions and system glitches. This step is critical, as incorrect information may give the wrong result.
- Develop a hypothesis
Based on the literature review and the analysis, theories and hypotheses of the root cause of the problem should be developed. The hypothesis must have solid reasoning and a concrete corrective action plan.
- Test your hypothesis
Create a test plan that will prove your hypothesis. Collaborate with the people in charge and conduct tests on the process. Take care to collect as much data as possible. Utilize cross-functional cooperation to get data on the effect of the tests on other parts of the process. Analyze data using Lean Six Sigma techniques and base your solution on the results.
- Recommend a solution
Recommend your solution to the main stakeholders, such as the process workers, departmental personnel, and management. Present your reasons and analysis to support your theory. Provide a plan that the organization can use to implement your solutions.
Also Read: What Is Process Capability and Why It’s More Interesting Than It Sounds
Tips for Executing Successful Green Belt Projects
A good Green Belt project can seal your position as an in-demand expert. Here’s how you can take your project from good to great.
- Record your daily interactions and observations and summarize them at the end of each day
- Clearly define the problem and goals and ensure each team member understands them
- Ensure clear and regular communication between team members and other departments
- Chart the various Lean Six Sigma tools and techniques your team knows and select the most useful ones for the project
- Plan the project path, allocate the tasks, and track the progress with regular updates and reviews
- Stress on regular and lucid data collection and documentation. Ensure they are accessible to all the team members
- Arrange for implementation of the solutions and use control measures to check for their efficacy
- Implement an efficient feedback loop and encourage your team members to give and receive criticism politely, respectfully, and usefully
- At the end of the project, conduct a thorough review of the pitfalls and mistakes made during the project, and provide an actionable plan to your team members, who can use these insights for their future projects
Master the Skills to Build Great Green Belt Projects
Problem-solving and maintaining product consistency are vital for any organization, but more so in a business environment that’s becoming more competitive than ever. The ability to drive successful Green Belt projects is a prized skill that puts you in an in-demand position. Acquiring these sought-after Six Sigma skills can open the door to excellent opportunities and pave the way for a shining career in quality management.
An industry-recognized Six Sigma program, such as the one offered by the University of Massachusetts, in collaboration with Simplilearn, can help you build a solid foundation in Lean management and Six Sigma Green and Black Belts.
The IASSC-accredited program provides a deep dive into quality management techniques based on the curriculum aligned with IASSC. Learn from industry experts and get hands-on training through case studies and capstone projects.
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