6S22147 Lean Six Sigma Green Belt Assessment Brief 2026 | QQI

Ensure that you include references to both lean and six sigma tools.

Take care to follow all phases of the DMAIC framework demonstrating your use of the lean and six sigma tools.

Please answer question 1.3 following points a  f listed below. Marks out of 12 available for each point are listed alongside each point.

• Project title, sector and industry
• Summary of Before and After Metrics
• Time (cycle time reduction achieved, hours and %)
• Quality (performance improved – number and %)
• Financial improvements achieved

• Problem Statement
• Baseline (performance before project)
• Improvement objectives

•       Summarise key tools used here

•       Insert diagram(s) as example(s)

•       Summarise key findings and metrics

•       Insert diagram of tools used

Summarise key improvements implemented

 Plan for control

Initiate your process improvement project (PIP) using a project charter template outlining a clearly scoped opportunity statement using time, quality, and financial metrics to describe the problem and its impact on the business.

Provide a short narrative to accompany the charter describing how you initiated the project.

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Identify, analyse and document your project stakeholders using the template provided, showing 5-8 stakeholders.

Using the insights gained from this exercise, devise a communication management plan for the different stakeholders. Please use the template provided.

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Consider how you would configure a balanced process improvement team taking account of:

• Diverse team roles (Thought, Action, People)
• Social Styles

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Examine and discuss:

• Voice of the Customer (VOC) and Voice of the Process (VOP) for your process improvement project.
• Document Critical to Quality (CtQ) characteristics.

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Using the SIPOC template provided, determine the high level process steps for your green belt project.

This should clearly show the inputs and outputs as well as suppliers and customers (recipients) for each step.

Aim for 5-8 process steps.

Using a Gantt chart, develop a high level project schedule showing key milestones at each phase of the DMAIC cycle.

An optional template is provided, but you are free to use your own.

Measure the baseline process performance using a current state Value Stream Map (VSM) and calculate time and quality metrics.

Your map should show both process flow and information flow.

Please answer this following points a –  g listed below. Marks out of 20 available for each point are listed alongside each point.

 Measure the baseline process by preparing a data collection plan using the template provided.

Your data collection plan should be suitable to produce run charts or control charts and pareto charts or histograms in the analyse stage of your project.

Conduct a Failure Modes & Effects Analysis (FMEA) to assess potential risk. Populate the template provided. Aim to show 6-8 risks.

Identify 3 insights based on your analysis.

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5

Refer back to your VSM,  ensuring that you look at both work flow and information flows.

•               Identify & document activities in the process which present obstacles to flow.

•               Highlight and categorise the process steps based on the VA, NVA, NNVA (Value Adds, Non-Value Adds and Necessary Non-Value Adds) method.

•               Analyse your time and quality metrics and identify targeted areas for improvement.

•               Comment on insights gained from this analysis and document potential target areas for improvement.

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Analyse your current state VSM. Identify and document forms of waste referencing TIMWOOD or similar.   You should look for an example of each of the 8 types of waste. If you feel there is no example for a particular type, then give a theoretical example that could apply to your process

Document target areas for improvement.

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• Conduct a team brain-storming session to analyse the potential cause of the problem identified and demonstrate cause-effect relationships. Display using a cause-effect diagram (Fishbone, Ishikawa).
• Drill down to the root cause(s) using the “5 Whys” questioning technique. Display an example of your 5 Why results (no template provided).
• Describe potential root causes. Provide an X-Y matrix showing how root causes were prioritised.

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Analyse the data collected in task 3.2 during the measure phase and establish patterns of variation. Display your results using a run or  control chart.

Provide a short narrative documenting insights gained  from these charts.

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Analyse the data collected in task 3.2 during the measure phase and categorise sources of variation using a pareto chart or histogram.

Provide a short narrative to interpret your findings

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4

Considering the findings from Tasks (4.1- 4.6), assemble the team and using a PICK chart, brain-storm potential countermeasures (potential solutions).

• Describe the countermeasures (one sentence each) and ask “What impact will this have on the problem?” and “How easy is it to implement?”.
• Plot the results on the PICK chart (no template provided).
• Provide a short narrative (in table or essay format) to justify the rationale used to prioritise these (aim for 6 – 10 countermeasures).

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Using the findings from the Analyse Phase and your countermeasures identified create a process improvement action plan using the template provided.

The action plan needs to be at the task level with identified resources (actionees), start/finish dates, and dependencies (which tasks precede other tasks).

Demonstrate the use of the PDCA/piloting approach.

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4

Demonstrate the use of team based approaches using lean six sigma tools. Choose from 3 of the following: Kaizen events, SMED, 5S, Kanban visual management, and Error Proofing. (3 marks each)

Provide insights on what you have gained from this exercise.

(1 mark each)

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Clearly show:

• Process blocks, resources, information flow.
• New improved time metrics and quantify any saving.
• New improved quality metrics and quantify any saving.

Summarise before and after improvements by comparing project outcome with the original problem statement / objective(s) / metrics contained in the charter.

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6

Create a process control plan to ensure that countermeasures are maintained and kept under the control of a process owner.

Choose any one from the following;

1.   Introduction of run/control chart

2.   Introduction of “leading” metrics

3.   5S – Sustain phase activities

4.  Visual management (Kanban) tools

5.   Establishing an ongoing FMEA risk analysis and response programme

Explain how standard work would be introduced or updated.

Discuss how it could be used as part of a training plan to ensure that the process improvement is embedded and will remain under the control of the process owner.

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Conduct a retrospective with the project team. Consider what went well, what did not go well, and what you would do differently for the next project along with lessons learned.

Identify and communicate future opportunities for your continuous improvement programme.

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