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Training Lean Six Sigma Green Belt – DMAIC, Process Improvement & Quality Improvement

Training Lean Six Sigma Green Belt merupakan program pelatihan intensif selama 5 hari yang dirancang untuk memberikan pengetahuan, keterampilan, dan kompetensi dalam menerapkan metode Lean Six Sigma untuk meningkatkan efisiensi, mengurangi pemborosan, mengurangi variasi dan defect, serta meningkatkan kualitas proses.

Program Lean Six Sigma Green Belt memadukan prinsip Lean, metodologi Six Sigma, pendekatan DMAIC, dan berbagai tools analisis berbasis data. Peserta dibekali kemampuan untuk mengidentifikasi peluang improvement, mendefinisikan masalah, mengukur kinerja proses, menganalisis akar penyebab, mengembangkan solusi, serta membangun sistem pengendalian untuk mempertahankan hasil improvement.

Training ini sangat relevan bagi perusahaan yang ingin membangun budaya Continuous Improvement, Quality Improvement, Operational Excellence, Waste Reduction, Defect Reduction, Cost Reduction, dan Data-Driven Problem Solving melalui pengembangan kompetensi Lean Six Sigma Green Belt.

Mengapa Training Lean Six Sigma Green Belt Penting?

Dalam proses bisnis maupun operasional, perusahaan dapat menghadapi berbagai masalah seperti defect, reject, rework, scrap, waiting time, excessive inventory, bottleneck, process variation, customer complaint, downtime, lead time yang panjang, serta Cost of Poor Quality yang tinggi.

Lean Six Sigma Green Belt memberikan kerangka kerja yang sistematis untuk mengatasi masalah tersebut menggunakan metodologi DMAIC – Define, Measure, Analyze, Improve, Control. Peserta tidak hanya mempelajari konsep, tetapi juga bagaimana menyusun dan menjalankan project improvement secara terstruktur.

Manfaat Training Lean Six Sigma Green Belt

Memahami prinsip Lean dan Six Sigma.
Memahami integrasi Lean dan Six Sigma dalam Process Improvement.
Mampu mengidentifikasi waste dalam proses bisnis.
Mampu meningkatkan aktivitas Value Added.
Memahami metodologi DMAIC.
Mampu menyusun Lean Six Sigma Project Charter.
Mampu mengidentifikasi Voice of Customer (VOC).
Mampu menentukan Critical to Quality (CTQ).
Mampu membuat Process Mapping dan Value Stream Mapping.
Mampu menyusun Data Collection Plan.
Memahami Process Variation.
Mampu menggunakan Quality Tools.
Mampu melakukan Root Cause Analysis.
Mampu mengembangkan solusi improvement.
Memahami Statistical Process Control.
Mampu menyusun Control Plan.
Mampu melakukan Poka-Yoke / Mistake Proofing.
Mampu melakukan standardisasi hasil improvement.
Mampu mempresentasikan Lean Six Sigma Project.
Mampu memimpin dan melaksanakan project Lean Six Sigma Green Belt.

Materi Training Lean Six Sigma Green Belt

HARI 1 – Introduction Lean Six Sigma & DEFINE

1. Introduction to Lean Six Sigma

Pengantar Lean Six Sigma.
Sejarah perkembangan Lean dan Six Sigma.
Konsep Lean Thinking.
Konsep Six Sigma.
Lean vs Six Sigma.
Integrasi Lean Six Sigma.
Quality Improvement.
Process Improvement.
Operational Excellence.
Continuous Improvement.

2. Lean Thinking Principles

Value.
Value Stream.
Flow.
Pull.
Perfection.

Lean Thinking membantu organisasi melihat proses berdasarkan nilai yang diterima pelanggan dan mengurangi aktivitas yang tidak memberikan nilai tambah.

3. Value Added & Non-Value Added

Value Added Activity.
Non-Value Added Activity.
Necessary Non-Value Added Activity.
Customer Value.
Business Value.
Waste Identification.

4. Identifikasi Waste

Transportation.
Inventory.
Motion.
Waiting.
Overproduction.
Overprocessing.
Defects.
Unused Employee Talent.

5. Six Sigma Fundamental

Six Sigma Philosophy.
Process Variation.
Defect.
Yield.
Sigma Level.
Customer Requirement.
Data-Driven Decision Making.

6. Peran Lean Six Sigma Green Belt

Green Belt Role.
Project Team Member.
Project Leader.
Process Improvement Facilitator.
Data Analysis.
Problem Solving.
Change Agent.

7. DMAIC Methodology

Define – mendefinisikan masalah dan tujuan improvement.
Measure – mengukur current performance.
Analyze – menemukan dan memverifikasi Root Cause.
Improve – mengembangkan dan mengimplementasikan solusi.
Control – mempertahankan hasil improvement.

DEFINE PHASE

8. Mendefinisikan Masalah & Tujuan Project

Business Problem.
Problem Identification.
Problem Statement.
Goal Statement.
Project Scope.
Project Objective.
Business Impact.

9. Input Process Output Diagram – IPO

Input.
Process.
Output.
Process Boundary.
Critical Process.
Process Relationship.

10. SIPOC Analysis

Supplier.
Input.
Process.
Output.
Customer.

11. Project Charter

Business Case.
Problem Statement.
Goal Statement.
Project Scope.
Project Team.
Project Timeline.
Expected Benefit.
Stakeholder Approval.

12. Voice of Customer (VOC)

Customer Needs.
Customer Expectations.
Voice of Customer.
Customer Complaint.
Customer Satisfaction.
Customer Requirement.

13. Critical to Quality (CTQ)

VOC to CTQ.
Critical Customer Requirement.
Measurable Requirement.
CTQ Characteristic.
Quality Performance.

14. Stakeholder Analysis

Identify Stakeholders.
Stakeholder Interest.
Stakeholder Influence.
Stakeholder Support.
Communication Requirement.

15. Cost-Benefit Analysis

Improvement Cost.
Expected Benefit.
Financial Impact.
Operational Impact.
Quality Impact.
Project Feasibility.

Workshop DEFINE

Identifikasi masalah.
Membuat Problem Statement.
Membuat SIPOC / IPO.
Mengidentifikasi VOC.
Menentukan CTQ.
Membuat Project Charter.
Analisis Stakeholder.
Cost-Benefit Analysis.

HARI 2 – MEASURE PHASE

16. Current State Process Mapping

Current Process.
Process Flow.
Material Flow.
Information Flow.
Process Time.
Waiting Time.
Bottleneck.
Waste.

17. Current State Value Stream Mapping (VSM)

Define Product / Service Family.
Map Current State.
Process Steps.
Cycle Time.
Lead Time.
Inventory.
Information Flow.
Material Flow.
Value Added Time.
Non-Value Added Time.

Workshop Current State VSM

Peserta mempraktikkan pembuatan Current State Value Stream Mapping untuk mengidentifikasi aliran proses, waste, bottleneck, waiting, inventory, dan peluang improvement.

18. Descriptive Statistics

Data Type.
Mean.
Median.
Range.
Variance.
Standard Deviation.
Minimum & Maximum.
Data Distribution Awareness.

19. Cost of Poor Quality (COPQ)

Internal Failure Cost.
External Failure Cost.
Reject Cost.
Rework Cost.
Scrap Cost.
Customer Complaint Cost.
Warranty Cost.
Lost Productivity.

20. Sigma & Yield

Defect.
Opportunity.
Yield.
First Pass Yield Awareness.
Sigma Level.
Process Performance.

21. Understanding Variation

Process Variation.
Common Cause Variation.
Special Cause Variation.
Within Process Variation.
Variation Reduction.

22. Data Collection Plan

What Data Is Required?
Operational Definition.
Data Source.
Measurement Method.
Sampling.
Frequency.
Responsible Person.
Data Validation.

23. Seven Quality Tools

Check Sheet.
Pareto Chart.
Histogram.
Scatter Diagram.
Cause-and-Effect Diagram.
Control Chart.
Flowchart / Stratification Awareness.

24. Box Plot

Median.
Quartile.
Interquartile Range.
Data Spread.
Outlier.
Comparing Groups.
Latihan Box Plot.

HARI 3 – ANALYZE PHASE

25. Root Cause Analysis

Symptom vs Root Cause.
Potential Cause.
Contributing Cause.
Root Cause.
Cause Verification.
Data-Based Analysis.

26. Pareto Analysis

Frequency Analysis.
Prioritization.
Vital Few vs Trivial Many.
Pareto Principle.
Problem Prioritization.

27. Fishbone Diagram

Man.
Machine.
Method.
Material.
Measurement.
Environment.

28. 5 Whys Root Cause Analysis

Problem Definition.
Why 1.
Why 2.
Why 3.
Why 4.
Why 5.
Cause Chain.
Root Cause Verification.

29. Data Analysis

Data Stratification.
Pattern Identification.
Trend Analysis.
Correlation Awareness.
Scatter Analysis.
Comparison Analysis.
Evidence-Based Root Cause.

30. Hypothesis Testing Awareness

Null Hypothesis.
Alternative Hypothesis.
Statistical Significance.
P-Value.
Statistical Decision.
Practical Significance.

31. FMEA Awareness

Failure Mode.
Failure Effect.
Failure Cause.
Severity.
Occurrence.
Detection.
Risk Assessment.
Recommended Action.

Workshop ANALYZE

Pareto Analysis.
Fishbone Diagram.
5 Whys Analysis.
Potential Cause Identification.
Data Analysis.
Root Cause Verification.

HARI 4 – IMPROVE PHASE

32. Generate Improvement Solutions

Improvement Opportunity.
Solution Generation.
Brainstorming.
Creative Problem Solving.
Alternative Solution.
Solution Prioritization.

33. Solution Selection

Impact.
Feasibility.
Cost.
Time.
Risk.
Customer Benefit.
Business Benefit.

34. Lean Improvement Tools

Kaizen.
5S / 5R.
Visual Management.
Standardized Work.
Poka-Yoke.
Flow Improvement.
Waste Elimination.
Pull System Awareness.
Kanban Awareness.

35. Future State Value Stream Mapping

Current State Review.
Waste Elimination.
Improved Process Flow.
Future State.
Reduced Lead Time.
Reduced Waste.
Improved Customer Value.

36. Pilot Improvement

Pilot Planning.
Trial Implementation.
Risk Assessment.
Performance Measurement.
Before vs After Analysis.
Improvement Validation.

37. Implementation Plan

Action Item.
Person in Charge.
Target Date.
Resources.
Expected Result.
Monitoring.

HARI 5 – CONTROL PHASE & POST TEST

38. Statistical Process Control (SPC)

Process Variation.
Process Stability.
Common Cause.
Special Cause.
Control Chart.
Control Limit.
Process Monitoring.

Statistical Process Control digunakan untuk membantu mempertahankan improvement dengan memonitor kestabilan proses dan mendeteksi perubahan yang memerlukan tindakan.

39. Control Plan

Critical Process Parameter.
Critical Quality Characteristic.
Measurement Method.
Control Method.
Frequency.
Responsible Person.
Reaction Plan.

40. Change Management

Stakeholder Engagement.
Communication.
Resistance to Change.
Employee Involvement.
Implementation Support.
Sustainability.

41. Standardization

Standard Operating Procedure.
Work Instruction.
Standardized Work.
Visual Standard.
Training.
Documentation.

42. Poka-Yoke / Mistake Proofing

Error Prevention.
Error Detection.
Defect Prevention.
Process Error Reduction.
Human Error Reduction.
Zero Defect Awareness.

43. Project Commissioning & Closure

Verify Project Result.
Verify Financial / Operational Benefit.
Project Documentation.
Transfer to Process Owner.
Lessons Learned.
Project Closure.

44. Presentation Skill

Project Storyline.
Presenting DMAIC Project.
Data Visualization.
Presenting Improvement Result.
Management Presentation.
Project Recommendation.

45. Post Test

Pada akhir program, peserta mengikuti Post Test untuk mengevaluasi pemahaman terhadap konsep, metodologi, dan tools Lean Six Sigma Green Belt yang telah dipelajari selama training.

Lean Six Sigma Green Belt & DMAIC

Fase	Fokus	Contoh Tools
DEFINE	Mendefinisikan masalah, customer requirement, dan tujuan project.	Project Charter, VOC, CTQ, SIPOC, Stakeholder Analysis.
MEASURE	Mengukur kondisi dan performance proses saat ini.	VSM, Data Collection Plan, Descriptive Statistics, COPQ, Yield.
ANALYZE	Mengidentifikasi dan memverifikasi Root Cause.	Pareto, Fishbone, 5 Whys, Data Analysis, FMEA.
IMPROVE	Mengembangkan dan mengimplementasikan solusi.	Kaizen, Poka-Yoke, Future State VSM, Pilot Improvement.
CONTROL	Mempertahankan hasil improvement.	SPC, Control Plan, SOP, Standardized Work, Monitoring.

Lean Six Sigma Green Belt untuk Manufacturing

Dalam Manufacturing, Lean Six Sigma Green Belt dapat digunakan untuk mengurangi defect, reject, rework, scrap, process variation, downtime, bottleneck, waiting, excessive inventory, unnecessary movement, dan berbagai waste yang memengaruhi Quality, Cost, Delivery, Productivity, dan Customer Satisfaction.

Lean Six Sigma Green Belt untuk Production

Pada Production, Green Belt dapat memimpin improvement project untuk meningkatkan output, yield, process capability, cycle time, productivity, process stability, serta mengurangi defect dan production loss.

Lean Six Sigma Green Belt untuk Quality Control & Quality Assurance

QC dan QA dapat menggunakan metodologi Lean Six Sigma untuk menganalisis defect, nonconformity, customer complaint, variation, inspection problem, Cost of Poor Quality, dan berbagai peluang Quality Improvement.

Lean Six Sigma Green Belt untuk Engineering

Engineering dapat menggunakan Lean Six Sigma untuk Process Improvement, Root Cause Analysis, equipment improvement, parameter optimization, failure reduction, dan peningkatan process performance.

Lean Six Sigma Green Belt untuk Service & Office

Lean Six Sigma tidak terbatas pada Manufacturing. Pendekatan DMAIC dapat digunakan untuk mengurangi waiting, approval delay, duplicated work, transaction error, document error, unnecessary handoff, customer complaint, dan proses administrasi yang terlalu panjang.

Lean Six Sigma Green Belt untuk Warehouse & Supply Chain

Pada Warehouse dan Supply Chain, Lean Six Sigma dapat digunakan untuk mengurangi inventory problem, picking error, delivery delay, excessive transportation, waiting, material handling waste, dan lead time.

Lean Six Sigma Green Belt & Minitab

Dalam project yang membutuhkan analisis statistik, Software Minitab dapat digunakan untuk membantu melakukan Descriptive Statistics, Graphical Analysis, Hypothesis Testing, Regression, ANOVA, Process Capability, MSA, SPC, dan Design of Experiments sesuai kebutuhan analisis.

Lean Six Sigma Green Belt & Root Cause Analysis

Pada fase Analyze, peserta perlu membedakan symptom dengan Root Cause. Tools seperti Pareto Chart, Fishbone Diagram, 5 Whys, Process Mapping, FMEA, dan analisis data dapat digunakan untuk mengembangkan serta memverifikasi potential causes.

Lean Six Sigma Green Belt & Process Capability

Process Capability membantu tim mengevaluasi kemampuan proses dalam memenuhi specification. Indikator seperti Cp, Cpk, Pp, dan Ppk dapat digunakan sesuai kebutuhan project setelah kestabilan dan kualitas data diperhatikan.

Lean Six Sigma Green Belt & Measurement System Analysis

Keputusan improvement membutuhkan data yang dapat dipercaya. Measurement System Analysis membantu mengevaluasi apakah variasi dari sistem pengukuran cukup memadai untuk mendukung analisis dan keputusan project.

Lean Six Sigma Green Belt & Design of Experiments

Untuk permasalahan yang membutuhkan pengujian beberapa faktor secara terstruktur, Design of Experiments dapat digunakan untuk menganalisis Main Effect, Interaction Effect, dan menentukan kombinasi process parameter yang lebih optimal.

Lean Six Sigma Green Belt & Operational Excellence

Kompetensi Green Belt mendukung Operational Excellence melalui kemampuan mengidentifikasi masalah, menganalisis proses, mengurangi waste dan variation, mengembangkan solusi, mengukur benefit, dan menjaga hasil improvement secara berkelanjutan.

Kompetensi yang Dikembangkan

Lean Six Sigma.
DMAIC Project Management.
Lean Thinking.
Waste Identification.
Value Stream Mapping.
Voice of Customer.
Critical to Quality.
Project Charter.
Data Collection.
Statistical Analysis.
Root Cause Analysis.
Process Improvement.
Quality Improvement.
Cost Reduction.
SPC.
Control Plan.
Poka-Yoke.
Continuous Improvement.
Project Presentation.
Operational Excellence.

Target Peserta Training

Training Lean Six Sigma Green Belt ditujukan bagi Supervisor, Manager, dan profesional yang bertanggung jawab terhadap peningkatan proses, Staff Quality Control / Quality Assurance, anggota tim project Lean Six Sigma, serta karyawan yang ingin memahami dan menerapkan prinsip Lean dan Six Sigma.

Program ini juga relevan bagi profesional Production, Manufacturing, Engineering, Maintenance, Warehouse, Supply Chain, Operations, Process Improvement, Business Process Improvement, Continuous Improvement, Operational Excellence, dan fungsi lain yang terlibat dalam project improvement berbasis data.

Team Trainer Johnson Indonesia

Hendra Feraldi, ST, IPM, BBLSS

Durasi Training

5 Hari Full Day dengan pembahasan bertahap mulai dari fundamental Lean Six Sigma, Define, Measure, Analyze, Improve, Control, hingga Post Test dan Project Presentation.

Jadwal Training Lean Six Sigma Green Belt

Periode	Tanggal Pelaksanaan
Juli 2026	27–31 Juli 2026
Agustus 2026	03–07 Agustus 2026
September 2026	21–25 September 2026
Oktober 2026	19–23 Oktober 2026
November 2026	23–27 November 2026
Desember 2026	14–18 Desember 2026
Januari 2027	11–15 Januari 2027
Februari 2027	08–12 Februari 2027
Maret 2027	22–26 Maret 2027
April 2027	19–23 April 2027
Mei 2027	24–28 Mei 2027
Juni 2027	21–25 Juni 2027

Catatan: Jadwal dapat mengalami penyesuaian. Peserta disarankan melakukan konfirmasi kepada Johnson Indonesia sebelum melakukan pendaftaran.

Fee Investasi Training

Offline Training Jakarta

Rp14.875.000/orang / 5 hari full day. Minimal pengiriman 3 peserta dan PASTI RUNNING di hotel.

Investasi termasuk Seminar Kit, Certificate, Lunch, Snack, dan Souvenir.

Offline Training Luar Kota Jakarta

Rp12.000.000/orang – PASTI RUNNING.
Rp8.500.000/orang – pengiriman 1–5 peserta.
Rp8.000.000/orang – pengiriman di atas 5 peserta.
Termasuk Seminar Kit, Certificate, Lunch, Snack, dan Souvenir.

Private Onsite Training

Private Onsite Training tersedia di Training Center Johnson Indonesia. Fasilitas mencakup Seminar Kit, Certificate, Lunch, Snack, dan Souvenir. Silakan menghubungi Johnson Indonesia untuk informasi investasi Private Onsite terbaru.

Online Training

Rp13.750.000/orang / 5 hari full day, pukul 09.00–16.00 WIB.

Perusahaan yang Telah Mengikuti Training Sejenis

PT Honda Prospect Motor

Daftar perusahaan dan institusi lain yang telah menggunakan layanan training Johnson Indonesia dapat dilihat melalui Daftar Client Johnson Indonesia.

Public Training Lean Six Sigma Green Belt

Johnson Indonesia menyediakan Public Training Lean Six Sigma Green Belt selama 5 hari untuk meningkatkan kompetensi profesional dalam menjalankan project Process Improvement menggunakan metodologi DMAIC dan berbagai Lean Six Sigma Tools.

In-House Training Lean Six Sigma Green Belt

In-House Training Lean Six Sigma Green Belt dapat disesuaikan dengan kondisi proses, KPI, defect, waste, Cost of Poor Quality, productivity problem, customer complaint, process variation, operational issue, serta target improvement perusahaan.

Perusahaan dapat menggunakan project atau kasus aktual sebagai bahan workshop sehingga peserta dapat mempraktikkan Define, Measure, Analyze, Improve, dan Control berdasarkan kondisi nyata di lingkungan kerja.

Training Terkait – Internal Link

Mengurangi Waste & Non-Value Added Activity

Lean Six Sigma Green Belt membantu peserta mengidentifikasi Transportation, Inventory, Motion, Waiting, Overproduction, Overprocessing, Defect, dan aktivitas lain yang tidak memberikan nilai tambah sehingga proses dapat dibuat lebih efektif dan efisien.

Mengurangi Defect & Process Variation

Pendekatan Six Sigma membantu peserta memahami variation dan menggunakan data untuk mengidentifikasi penyebab defect, reject, rework, scrap, maupun masalah kualitas lainnya.

Meningkatkan Produktivitas & Process Performance

Dengan mengurangi waste, bottleneck, waiting time, process variation, dan aktivitas Non-Value Added, perusahaan dapat meningkatkan produktivitas serta performance proses secara lebih terstruktur.

Meningkatkan Kemampuan Problem Solving Berbasis Data

Green Belt diarahkan untuk tidak mengambil keputusan improvement hanya berdasarkan asumsi. Problem solving dilakukan dengan menggabungkan process knowledge, fakta, data, statistical analysis, dan Root Cause Verification.

Memimpin Project Continuous Improvement

Kompetensi Green Belt membantu peserta menjalankan project improvement mulai dari penyusunan Project Charter, pengumpulan data, Root Cause Analysis, implementasi solusi, pengukuran benefit, hingga Control dan standardisasi.

Lean Six Sigma Green Belt Project

Project Green Belt dapat diarahkan pada permasalahan seperti defect reduction, Cost of Poor Quality reduction, cycle time reduction, productivity improvement, yield improvement, customer complaint reduction, process variation reduction, inventory reduction, lead time reduction, service improvement, maupun berbagai target bisnis lainnya.

Mengapa Memilih Johnson Indonesia?

Johnson Indonesia – Training Provider Since 2002 menyediakan Public Training, In-House Training, Corporate Training, Private Training, Offline Training, dan Online Training untuk pengembangan kompetensi Lean Six Sigma, Quality Management, Manufacturing, Production, Engineering, Statistical Analysis, Problem Solving, Continuous Improvement, dan Operational Excellence.

Melalui Training Lean Six Sigma Green Belt, peserta memperoleh pembelajaran intensif selama 5 hari mengenai Lean Thinking, DMAIC, Project Charter, VOC, CTQ, VSM, Statistical Analysis, Cost of Poor Quality, Root Cause Analysis, Improvement, SPC, Control Plan, Poka-Yoke, standardisasi, serta kemampuan memimpin project improvement.

Pendaftaran Training Lean Six Sigma Green Belt

Tingkatkan kompetensi tim dalam memimpin project improvement, mengurangi waste dan defect, meningkatkan kualitas, produktivitas, efisiensi, serta membangun budaya Continuous Improvement melalui Training Lean Six Sigma Green Belt Johnson Indonesia.