Program Overview

Introduction to the Yellow Belt Module

The Yellow Belt Module is a comprehensive program designed to introduce students to the fundamental principles of lean enterprise and six sigma methodologies. The program consists of nine modules, each focusing on a specific aspect of lean manufacturing and problem-solving.

Overview of the Yellow Belt Module

The Yellow Belt Module is designed to provide students with a thorough understanding of lean tools and techniques, including 5S, Pull System, SMED, Level Loading, and Takt Time. The program also covers leadership in a continuous improvement culture, aligning the organization, and understanding customers and processes.

Module 1 - Lean Enterprise Overview

In this module, students are introduced to the basic knowledge of lean enterprise, including the Bose Lean Enterprise Vision and House of Bose. The module features a simulation game using Lego to simulate the assembling process in a manufacturing line, where students apply lean tools to enhance each run.

Module 2 - Leadership in a Continuous Improvement Culture

This module focuses on leadership in a continuous improvement culture, featuring a sharing session with a Business Excellence Manager from Flextronics Systems Penang Sdn. Bhd. Students learn about the characteristics of lean leaders and the importance of management and leadership in a lean organization.

Module 3 - Aligning the Organization

In this module, students learn about lean manufacturing through topics such as changes in management, strategy deployment, and core business process. The module features interactive materials, including videos and figures, to enhance understanding.

Module 4 - Understanding Customers and Processes

This module emphasizes the importance of understanding customers and processes in a lean organization. Students learn about creating an IPO, SIPOC, and Value Stream Map (VSM) and are introduced to concepts such as SMART Goals, Project Prioritization Matrix, and process improvement.

Module 5 - Lean and Problem-Solving Fundamentals

In this module, students learn about the Plan, Do, Act, and Check (PDCA) technique and its 12 phases. The module features a simulation game, Help Simulation, where students practice organized problem-solving using lean foundation elements.

Module 6 - Lean and Problem-Solving Fundamentals

This module continues to explore the PDCA cycle, focusing on the first three phases of the Plan phase. Students learn about process maps, graphic analysis, and SMART goals, and participate in a practical simulation to identify performance improvements.

Module 7 - Analysis Tools and Standards

In this module, students learn about tools such as "5 Why" and "Cause & Effect Diagram" to identify core reasons. The module also covers graphical analysis approaches, including the Pareto chart, and emphasizes the importance of data collection and fundamental calculations.

Module 8 - Analysis Tools and Standards

This module focuses on discipline as a fundamental aspect of a successful PDCA problem-solving strategy. Students learn about stages such as "Identify, Develop & Test, Refine & Finalize, and Implement Countermeasures" and recognize the importance of following up and tracking progress.

Module 9 - Basic Statistics and Lean Management Systems

In this final module, students learn about basic statistics, including creating histograms and control charts. The module also covers the PDCA 12-step template and features a refresher session to ensure understanding of each step in the PDCA cycle.

Program Details

• The program consists of nine modules, each focusing on a specific aspect of lean manufacturing and problem-solving.
• The program is designed to provide students with a thorough understanding of lean tools and techniques.
• The program features interactive materials, including videos, figures, and simulation games, to enhance understanding.
• The program emphasizes the importance of leadership, management, and customer understanding in a lean organization.
• The program covers various topics, including 5S, Pull System, SMED, Level Loading, Takt Time, and PDCA.