Controlling and Sustaining Improvement Training

Overview

This Control phase and sustainability training develops strong skills in maintaining and institutionalizing process improvements using Lean and Six Sigma practices. You learn how to apply Lean controls, visual management, 5S, Kanban, and mistake proofing to standardize work, reduce variation, and prevent errors. The course also covers Six Sigma control plans, cost benefit analysis, ROI and ROA measurement, response planning, and project closure to ensure improvements deliver consistent performance and long term business value. By the end of this course, you will be able to: - Apply Control Phase Practices: Sustain improvements using Lean controls, visual management, and standard work - Use Lean Control Tools: Implement 5S, Kanban, and Poka Yoke to manage workflow and prevent defects - Build Six Sigma Control Plans: Define metrics, response plans, and governance to maintain gains - Measure Financial Impact: Assess cost benefit, ROI, and ROA to validate business value Ideal for professionals seeking to move from implementation to sustained results in Lean Six Sigma projects. Prior knowledge of Lean Six Sigma fundamentals and DMAIC phases is recommended.

Syllabus

Lean Controls

This module explains how to sustain process improvements using Lean controls and the Control phase. Learners understand Control phase objectives, apply visual management through 5S practices, and use Kanban principles to manage workflow and reduce variation. The module also covers mistake proofing with Poka Yoke techniques, real examples, and key takeaways to ensure consistent performance, standardization, and long term operational stability across processes.

Six Sigma Control Plans

This module focuses on building effective Six Sigma control plans to sustain improvements and deliver measurable financial impact. Learners assess project cost benefit, calculate ROI and ROA, and apply structured cost benefit analysis to guide control planning. The module covers control plan elements, response planning, and project closure practices to ensure gains are maintained, risks are managed, and improvement initiatives deliver long term business value.