Lean Green Belt

Duration: 5 days includes successful delivery of a live project

Who is this for?

Green Belts are usually departmental managers/change leaders or project managers who are looking to drive change in their respective roles and areas of responsibilities. They want to know what tools to use and when and become proficient at choosing the best framework for their needs. They reinforce the theory learned by putting everything gained throughout their training into real life projects that deliver huge benefits and savings – all achieved during the duration of the training programme.

Contact Ian on +353-86-1557000 or ian@bpsolutions.ie  to see how you can avail of this training that delivers huge benefits through delivering real live projects in your organisation.

Programme Objectives

The objective of this programme is to enable all employees to develop their ‘Lean’ skills and become immersed in ‘Lean’ thinking, learn how they can apply these new skills across the whole organisation and for managers to ensure that these are continuously cascaded to their teams. This programme will enable and motivate all staff to instil and promote a change in culture and promote a problem-solving organisation striving to deliver an exceptional patient experience using ‘Lean’ philosophy, principles, and tools in a clinical healthcare environment. It builds upon the yellow belt programme and goes into depth on the diverse types of process maps, when to use them and why. A project will be completed during the course duration that follows the course structure and ensures a ‘hands on’ approach and application of course learning.

By the end of this green belt programme, you will:

  • Be introduced and understand ‘Lean’ and Lean thinking, understand the Lean methodology, principles of Lean, waste reduction, value creation and the importance of always looking to achieve continuous improvement and quality within the organisation
  • Understand how you and your team(s) can use these tools and techniques within your own organisation
  • Be able to lead initiatives using Lean skills and Lean management techniques and cascade/support to teams
  • Have been introduced and delve into tools and structures that can continually be applied across the organisation.
  • Participate and lead in a culture of continuous improvement through collaboration with colleagues
  • Challenge how/why tasks are completed
  • Use structured root cause analysis techniques to identify action plans and drive process improvements
  • Understand and demonstrate the importance of measuring and delivering core benefits across the organisation that are aligned to strategic targets
  • Tackle projects with confidence that follow a structured project/process approach
  • Celebrate success and help share best practice through the use of A3 Storyboards

Course Duration

This programme will be delivered over an agreed period of time by way of 5 days training.

Course Outline

  • The trainer for the programme will be Ian Gourlay
  • Training for this module will be 100% classroom instruction
  • Total net training programme time = 5 days
  • Award for certification will be 50% assessment and 50% project submission


  • Day 1 – Lean thinking, Lean mindset, Lean principles, 8 Wastes, Value Add, Non-Value Add, Mura, Muri, Muda, Creating problem statements and process charters
  • Day 2 – DEFINE – Review charter (inc project team and RACI). Validate problem statement (inc. financials). High level Value stream map/SIPOC. Create communication plans, elevator speech, threats, and opportunities, develop project schedule (inc. baseline data), Critical to Quality (CTQ) and CTQ Tree’s
    – MEASURE – Process Mapping (review all types of process maps and when to use). Identifying inputs/outputs, data collection plans, validate measurement system, collect baseline data, determine process capability. Standard work, Visual management
  • Day 3 – ANALYSE – Develop AS-IS process map, Problem solving, looking at and comparing different methodologies, root cause analysis, Cause & Effect, Ishikawa, 5 Whys. Estimate impact of root cause (FMEA), A3 generation, 5S
  • Day 4 – IMPROVE – Develop potential solutions, evaluate, and select best solutions, FMEA, action plans, pick chart, creative thinking, influencing stakeholders, comms plans, develop ‘SHOULD-BE’ process map, confirm against project goals, graphical analysis (before v after), develop implementation plan
  • Day 5 – CONTROL – Implement mistake proofing (POKA YOKE), develop SOP’s, standard work (documents), training plan and process controls, control plan, benefit tracker, implement solution & ongoing process measurements, identify opportunities to apply lessons learned

The above training and theory are complemented by following a real ‘patient journey’ process flow (how to map and the inclusion of issues, opportunities for improvement etc.) in the class. This reinforces the learning and tools and techniques and how to apply them.

Attendees in their groups also bring back progress made during their own projects, and these are discussed during the training sessions in preparation of the final project submission.

Training is externally accredited by the Institute of Industrial Engineers (IIE). I have worked with IIE for many years now. They were founded in 1955 and celebrated their golden jubilee in 2005. In 1996, the Institute became the 79th chapter of the American Institute of Industrial Engineers.