Honeywell Green Belt Training

Module 0

What you need to know

before you enroll in training
Scope

This Specification:

• Applies to both Core GB and DFSS GB

• Includes both the Module Zero, which is used to

explain program requirements to Managers and
Candidates (preferably before being enrolled into
training), and GB Certification requirements for all
“active” GB programs.
Table of Contents

1. Background
- Six Sigma at Honeywell
- Role of the Green Belt
- Who Needs GB certification
 Mandatory Honeywell Requirement

- Activity of the Green Belt Candidate

- Different GB Programs
2. Project Chartering
3. Pre-Work
4. Training
5. Project Work
6. Certification
 Six Sigma at Honeywell
A Vision
- Improved Quality and Speed
A Strategy
- Foundation for HOS/VPD/FT
- Accelerate Improvement
A Methodology
- Standard Approach
- Common Language
- Process Improvement/Problem Solving Tool Set
A Measurement
- probability of meeting customer expectations

The Term “Six Sigma” is used in Multiple Contexts

Evolution of Six Sigma at Honeywell

Six Sigma
Became foundation 2006
for HOS, VPD, FT

Six Sigma Plus

Incorporated Six Sigma,
Lean, HQV, Customer 2001
Excellence, TQM, HPWO
into one program
Various
Improvement
Programs, not 1994
Always Linked
TQM
Early 1990’s
C2I

Continuous Improvement is the Way We Work

Six Sigma at Honeywell

Waste Elimination (Lean) Variation Reduction

• Producing • Methodologies of Defect
- What is Needed, prevention
- When it is Needed, • Use of Statistical Tools that
- In the Exact Amount range from:
Requested by Customer - Process maps to
- Designed Experiments.
• With the Minimum Amount
of:
- Materials,
- Equipment, “Identify, understand and
- Labor, and AND eliminate sources of variation to
enhance the quality, yield and
- Space.
cost of products, processes and
services.” Quote by M. Harry
Honeywell Six Sigma Levels of Achievement

4 - Master level
Master Black Belt
Lean Master
Certification Programs Centered
3 - Expert level
Around Delivering Business
Black Belt
Results
Lean Expert

2 - Green Belt level

Core GB
DFSS GB

1 - Fundamentals Awareness of Six Sigma Concepts

Four Tiers of Six Sigma Offerings

A Standard Approach to Problem Solving and
Process Improvement…

DMAIC and PDCA

Problem or Opportunity is Recognized

D Stop and notify appropriate personnel “Andon”

Grasp the Facts

Problem identification
PLAN
Find ‘Point of Cause”
M 5W’s & 1H and Cause and Effect (6M’s)

A Find the Root Cause

5 Why Analysis

I Implement Solution
Prevent Re-occurrence
DO
Evaluate CHECK
C Did it Work?

Standardize ACT
 Six Sigma as a Measurement
• Sigma (standard deviation)
- A measure of variation (dispersion from the mean)
• Benchmark Sigma level is a measure of quality
- Process or product variation compared to specifications
Sigma DPMO Yield COPQ

6 3.4 99.9997% <10% World Class Benchmarks

5 233 99.976% 10-15% 10% GAP
4 6,210 99.4% 15-20%
Industry Average
3 66,807 93% 20-30%
10% GAP
2 308,537 65% 30-40%

1.5 500,000 50% >40% Non Competitive

DPMO = DEFECTS PER MILLION OPPORTUNITIES
COPQ = COST OF POOR QUALITY
Source: Journal for Quality and Participation, Strategy and Planning Analysis
 Six Sigma as a Common Language

DOE Balanced Process

Thought
Production Capability Process
Map

Seven Value
Added
Categories of Percentage
Waste
FMEA
D P MO
Cause &
Effect
Process Standardized
Map Work Kaizen

Every Honeywell Employee Understands the Language

of Process Improvement and Problem Solving
Role of the Honeywell Green Belt

• Pursue continuous improvement as a part of their

daily job
• Apply Six Sigma concepts and tools
• Identify process improvement opportunities
through the analysis of facts and data
• Coordinate your activities and receive mentoring
from Black Belts or Lean Experts when needed
• Share knowledge and best practices

Green Belts are Members of

Natural Work Teams
 Mandatory GB Training & Certification

• For Band 5 and above:

- Within 1 year of the start of their role.
• For Band 3 employees and above:
• SAP, • ISC
• HOS, • Engineering/
• VPD & Technology
• FT • IT

Within 1 year Within 2 years

GB program is open to all, and Mandatory to some

 Activity of the Green Belt Candidate, Core GB Example

n
Pre Project Pre-Work Training Post Work a tio
Problem Solving,
rtific
Project Chartering Process Improvement C e

• Candidate and • Manager • Pre-work material sent • Thought • Basic • Candidate • Candidate
Manager assigns cert to GB candidate by Process Stats applies documents tool
review GB project LMS Map learning to application
• Control project
Mod 0 (aligned to •Welcome Letter • DMAIC Charts • Mentor completes
business
• Candidate •E-Learning Modules • Candidate candidate’s
needs) • SIPOC • MSE
may have •Sample Project Charter uses technical
already taken • Project Mentor •Green Belt Module 0 • Process • Process advanced evaluation
one-day Six is assigned Map Capability tools as
• Candidate & Mgr • Candidate's
Sigma required
• Develop complete final project • C&E • Visual Manager
Fundamentals project scope charter Matrix Mgmt • Candidate completes
Training utilizes business impact
• Determine • Review e-learning • FMEA • Standard mentor for evaluation
appropriate Modules for Work
• Waste technical or
Green Belt, introduction to: • Certification sign-
• Control business
i.e. Core or •What are Six Sigma and • Batch vs. guidance off document
Lean Plans
DFSS Flow completed
•y=f(x) • Manager
• Nice to
• Schedule •Value Stream Concept • Work Load ensures • Update training
Know
training via the •SIPOC Balance candidate records
Section
Learning •Process Mapping stays aligned
• Activity
Management •Value Added Flow Analysis • Where to to business
System (LMS) Chart Go Section needs
•Cause & Effect Matrix
• Rapid
Problem • Lean/Six
Solving Sigma
(PDCA) Tool Book
Table of Contents

1. Background
2. Project Chartering
• Role of Manager and GB Candidate
• Identify Business Sponsor
• Identify Mentor
• Identify Appropriate GB Program
3. Pre-Work
4. Training
5. Project Work
6. Certification
Project Chartering – Role of Manager and GB Candidate

1) Manager aligns GB Candidate to a key business opportunity

within scope of business/functional area
2) Manager and GB Candidate develop project charter
3) Manager and GB Candidate select appropriate GB program to
implement opportunity
3) Manager and GB Candidate select appropriate Mentor
4) Manager and GB Candidate identify and validate appropriate
project Sponsor
5) GB Candidate signs up for training

6) Candidate completes training

7) Candidate completes project and demonstrates positive
business results
8) Mentor completes Certification process
Roles and Responsibilities

Manager/Mentor Candidate
Identify
key business opportunity
Develop
Project Charter

Select appropriate GB program, Mentor, Sponsor

Sign off on Charter

Sign up and attend
Provide mentoring on
training
business issues and tool
usage Complete
training & project

Complete GB Certification
Identify Project

• Project must be aligned with the Function,

Organization and/or Enabler Goals
• Project must be aligned with the employee's job
responsibilities
• Project must be aligned to candidate’s and/or
Manager’s Goals and Objectives (HPD)
• Project must meet the SMART criteria
Specific
Measurable (From present level to target level)
Aggressive Yet Achievable
Relevant to Business
Time Bound
Identify Business/Project Sponsor

• First Choice for Business Sponsor should be GB

Candidate’s Manager or someone who:
- Is a natural owner of the project area
 Will benefit from the project results
 Has a vested interest in the project being completed
 Is in a position to remove barriers
- Drives completion of the Project
- Attests to the “organizational impact” of the
project.
Project Chartering - Identify Mentor
• Green Belt Candidate's Mentor should be chosen
from one of these groups:
- Immediate Manager (if Certified as GB or Higher)
- Certified BB / BB Candidate
- Certified LE / LE Candidate
- Certified Master /Master Candidate
• The Mentor will:
- Guide tool understanding and application
- Complete technical assessment.
- Coordinate organization impact documentation
- Assist in the administrative closure of getting certification
recorded in HR profile and issuing a certificate.

“Active”, not “Passive”, Mentoring Required

Select GB Program

• Green Belt Core

- General problem solving and process improvement methodology using Six
Sigma and Lean tools.
- Anyone who does not deal directly with Honeywell IP or who has a process
improvement project should take this course.

• Green Belt DFSS

- Design methodology for products, systems and services along with general
problem solving and process improvement methodolocy using Six Sigma
and Lean tools.
- Anyone who deals with Honeywell IP or is designing a new process,
product, service, or system should take this course.
Scope and Timing of Certification Project

• Expectation is that all GB projects are scoped to

enable completion within 3 to 6 months of training
date.
- Please check with your SBG Core Team for additional (or
specific) requirements.
Table of Contents

1. Background
2. Project Chartering
3. Pre-Work
• Complete e-Learning Modules
4. Training
5. Project Work
6. Certification
 Core Green Belt Pre-Work
Candidate
Registers for Green Belt
Class in LMS
• Candidate registers for
class
•Receive Confirmation Email
from the Learning
Management System (LMS)
•Welcome Letter with
instructions attached
All steps must be completed prior to class
Candidate registers for
account with Moresteam
University for online pre-
work
• Candidate will receive an • Online Modules include
confirmation email from
Moresteam to start online
training
Post Work
Candidate
Candidate completes brings completed
online pre-work charter to class for
admissions ticket
• Candidate and Manager
an introduction to: complete a final project
•What are Six Sigma and charter
Lean
• Candidate brings
•y=f(x)
•Value Stream Concept
completed charter to
class and presents to the
•SIPOC
instructor to receive an
•Process Mapping
admissions ticket
•Value Added Flow Chart
•Cause & Effect Matrix
DFSS Green Belt Pre-Work
Candidate
Registers for Green Belt
Class in LMS
• Candidate registers for
class
•Receive Confirmation Email
from the Learning
Management System (LMS)
•Welcome Letter with
instructions attached
All steps must be completed prior to class
Candidate
brings completed
charter to class
• Candidate and Manager
complete a final project
charter
• Candidate brings
completed charter to
class
Table of Contents

1. Background
2. Project Chartering
3. Pre-Work
4. Training
5. Project Work
6. Certification
Core GB Training - PowerPoint vs. Museum Theft Theme

PowerPoint Based Core GB Museum Theft Theme Core GB

TMAP
TMAP
SIPOC
SIPOC
Process Map
Process Map
C & E Matrix
Measuring and Controlling Variation
Failure Modes and Effects Analysis
Measurement System Evaluation
Control Charts
Failure Modes and Effects Analysis
Measurement Systems Evaluation
Waste Elimination
Process Capability
Value Stream Mapping
Value Stream Mapping
Activity of the Product, Person and Machine
Waste Identification
Visual Management
Batch vs. Flow
Rapid Problem Solving
Workload Balance
Mistake Proofing
Activity Analysis
Standardized Work
Rapid Problem Solving
Control Plans
Visual Management
Standardized Work
Control Plans
 Old DFSS vs. New DFSS
DFSS-Hardware

DMAIC
Waste Elimination (Lean)
Basic Stats Variation Reduction
Advanced Statistics Utilize the Enablers
VOC

DFSS-Software VPD
DMAIC
Advanced Statistics
Basic Stats
Software Process
Software Process

Lean
Consolidated DFSS
DFSS-Systems/Services DMAIC
DMAIC
Basic Stats
Basic Stats
VOC VOC
Lean Lean

Eliminate Waste and Reduce Variation through Consolidation
Training Code of Conduct

• Attend ALL modules of the training

• Be on time:
- For beginning of class session
- For breaks (leave and return on time)
• During the sessions, except during breaks
- NO Meetings
- NO Phone calls
 Cell phones OFF
- NO Messages
 Pagers and Blackberries OFF
 NO Email
- Laptops CLOSED not required for class room exercises
Fulfill Work Responsibilities
Before or After Class
Table of Contents

1. Background
2. Project Chartering
3. Pre-Work
4. Training
5. Project Work
6. Certification
Project Completion

1) Manager aligns GB Candidate to a key business opportunity

within scope of business/functional area
2) Manager and GB Candidate develop project charter
3) Manager and GB Candidate select appropriate GB program to
implement opportunity
3) Manager and GB Candidate select appropriate Mentor
4) Manager and GB Candidate identify and validate appropriate
project Sponsor
5) GB Candidate signs up for training

6) Candidate completes training

7) Candidate completes project and demonstrates positive
business results
8) Mentor completes Certification process
Table of Contents

1. Background
2. Project Chartering
3. Pre-Work
4. Training
5. Project Work
6. Certification
GB Certification

1. Candidate Completes training requirement

(verified through LMS Records)
2. Mentor attests to application of tools toward
completion of GB certification project (via
Technical Assessment)
3. Business Sponsor attest that GB certification
project has had or will have a positive business
impact (via Organizational Impact Form)
Technical Assessment

• Candidate and Mentor choose the appropriate

Technical Assessment form to show which tools
were applied to project

- Core GB, mid 2008 to present (Museum Theft Theme)

- DFSS, 2009 and beyond, consolidated curriculum

- In Appendix:
- Core GB, prior to mid 2008 (PowerPoint based training)
- DFSS, prior to 2009, separate curriculums for HW, SW,
Systems & Services (see appendix for forms)
Core GB - Technical Assessment, Museum Theft
Theme
Skills Acquisition Assessment

Tools and/or Concepts Min. level Actual

TMAP 3 3

Variation Reduction
application on 4 additional tools.
indicated on all tools, plus show
SIPOC 3 3
Must demonstrate min level

Process Map 3 4
C&E Matrix 3 3
Failure Modes and Effects Analysis (FMEA) 3 3
Control Charts 3 4
Measurement System Evaluation (MSE) 3 3
Process Capability 3 3
Value Stream Mapping 2 2
Waste Elimination

Waste Identification 3 3
Batch vs Flow 3 4
Workload Balance 3 3
Activity Analysis 3 3
Rapid Problem Solving 3 3
Visual Management 3 4
Standardized Work 3 3

Req'd 4
Control Plans 4
Total Score 51 55

The candidate must achieve at least the minimum level listed for each tool (a 2 or 3
depending on the tool). In addition, the candidate must demonstrate applications in at
least four of the tools. The selected four tools for application will depend on the project

TECHNICAL SCORING KEY

1 Awareness
2 Understands Basic Concepts
3 Understands Concepts & Mechanics
4 Above + Demonstrates One Application
DFSS GB (consolidated) - Technical Assessment,
2009 and beyond
Green Belt, all programs – Organizational Impact

These are guidelines for the coach and manager in evaluating candidates
for certification. Both a technical and organizational assessment must be
GB Certification Asssessment completed to award certification.
Certification Criteria are to be assessed on an individual basis, even
for team projects
Candidate Name:
Location:
Certification Date:

Enter scores in cells as

Organizational Impact Assessment
appropriate, totals are

Criteria Min. Level Actual Anchors

Finds opportunities for process improvement efforts to increase

all of these requirements must

Identifies improvement opportunities within individual work

A A productivity and value and reduce cost, waste and defects.
processes

Acts on facts based in data

Uses Data-driven (DMAIC) approach to decision making A A
Exhibits critical thinking in approch
be met

Skilled in tool mechanics

Effectively applies proper Six Sigma tools
Sustains Measureable Results
Effectively communicates Six Sigma tools and results
A A Effectively deploys tools to get needed results
Seeks help when appropriate
Creates linkage between needs and effots
A A Can demonstrate independent measurement of results
Ensures results are sustainable/establish control plan
Able to explain linkage between tool applications and results
A A Effective team member/leader.
Shares best practice examples.

B Below GB Standard. Failed to make a positive effect with this behavior.

At GB Standard. Successfully/correctly made an impact with this

A
behavior.

Exceeded GB Standard. Consistently/correctly made an impact with

E
this behavior.
Green Belt, all programs - Sign-off Document

No
Yes
Certification Requirements Summary Required Actual
these are

Completed GB training Yes Yes

All of

req'd

Made Positive Impact toward Business goals Yes Yes

Performed improvement activities using the tools Yes Yes
Certification Req'ts. Complete Yes Yes

Reviewers:
BB or LE:
Chartering Manager (or Sponsor) Signature
Manager:

Internal use only:

Mentor Signature (BB or LE)

Training Records updated in PeopleSoft? __________(Mentor Initials)

Manager's Signature (if different than the Chartering Manager)
Certificate Requested?______________________(Mentor Initials)
Certificate Delivered?_______________________(Mentor Initials)
 Appendix

Pre-2009
DFSS and Core GB Technical
Assessments
Core GB - Technical Assessment, PowerPoint Based
Skills Acquisition Assessment

Tools and/or Concepts Min. level Actual

TMAP 3 3
application on 4 additional tools.
indicated on all tools, plus show

Reduction
SIPOC 3 3

Variation
Must demonstrate min level

Process Map 3 4
Measuring and Controlling Variation 3 3
Measurement System Evaluation 2 2
Failure Modes and Effects Analysis (FMEA) 3 4
Waste Elimination (VA/NVA) 3 3
Waste Elimination

Value Stream Mapping 3 3

Activity of The Product, Person & Machine 3 4
Visual Management 3 3
Rapid Problem Solving 3 3
Mistake Proofing 3 4
Standardized Work 3 3
Six Sigma Plus Concepts 2 2
Req'd Control Plans 4 4
Total Score 44 48
(*)General Scoring Guidelines:
The candidate must achieve at least the minimum level listed for each tool (a 2 or 3
depending on the tool). In addition, the candidate must demonstrate applications in at
least four of the tools. The selected four tools for application will depend on the project

TECHNICAL SCORING KEY

1 Awareness
2 Understands Basic Concepts
3 Understands Concepts & Mechanics
4 Above + Demonstrates One Application
 DFSS HW GB -Technical Assessment, prior to 2009
Skills Acquisition Assessment
Concept / Tool Min. level Actual Notes/Comments

TMAP 3 3

SIPOC 3 3
DMAIC

Process Map 3 3

Failure Modes and Effects Analysis (FMEA) 3 4

All of these tools/skills must be demonstrated to the level indicated, with four (4) applied for a score of 4.

Control Plans 3 3

DFSS Concepts 2 2

HDP & VPD 2 2

Customer Focused QFD 3 3

TECHNICAL SCORING KEY
1 Awareness
Modified Pugh Concept Selection 3 3
2 Understands Basic Concepts
Probability & Statistics 3 3 3 Understands Concepts & Mechanics
4 Above + Demonstrates One Application
Function Map 3 3

Transfer Functions & Regression 2 2

Control Charts 3 3

Process Capability (Variables Data) 3 3

DFSS

Statistical Analysis 3 4

Process Capability (Attribute Data) 3 3

SigmaScore 3 4

DFMA&T 2 2

MSE 3 3

DOE 3 3

Robustness & Optimization 3 3

Reliability 3 4

Verification 3 3

Total Score 65 69

(*)General Scoring Guidelines:

The candidate must achieve at least the minimum level listed for each tool (a 2 or 3 depending on the tool). In addition, the candidate must demonstrate
applications in at least four of the DFSS tools. The selected four tools for application will depend on the project needs and must be approved by the
candidate's mentor. If the candidate's business requires a "project" for certification, the candidate is required to present a Control Plan, which is in
addition to the requirement for four DFSS tools.
 DFSS SW GB - Technical Assessment, prior to 2009

Skills Acquisition Assessment

Concept / Tool Rec. level Actual Comments
DMAIC Basic DMAIC Concepts 2 2
Variation Concepts 2 2
Lean Concepts 2 2
Thought Process Map 3 3
NEM (including Control Charts) 3 3
Measurement System Evaluation 3 3
Control Plans 3 3
DFSS Basic DFSS Concepts 2 2
HDP 2 2
Product CTQs 3 3
Quality Function Deployment (QFD) 3 4
Requirements/Systems Engineering 3 3
Process & Function Mapping 3 4
FMEA (Process, Design) 3 3
DOE & Regression 2 2
Peer Reviews & Inspections 3 4
Estimation 3 3
SW Scorecard 3 4
Tools Applied 48 52
(*)General Scoring Guidelines:
The candidate must achieve at least the minimum level listed for each tool (a 2 or 3 depending on the tool). In addition, the candidate
must demonstrate applications in at least four of the DFSS tools. The selected four tools for application will depend on the project needs
and must be approved by the candidate's mentor. If the candidate's business requires a "project" for certification, the candidate is
required to present a Control Plan, which is in addition to the requirement for four DFSS tools.

TECHNICAL SCORING KEY

1 Awareness
2 Understands Basic Concepts
3 Understands Concepts & Mechanics
4 Above + Demonstrates One Application
 DFSS Systems & Services GB - Technical Assessment
prior to 2009

Skills Acquisition Assessment

Concept / Tool Rec. level Actual
DMAIC Basic DMAIC Concepts 2 2
Variation Concepts 2 2
Lean Concepts 2 2
Thought Process Map 3 4
Measurement System Evaluation 3 3
Control Plans 3 4
FMEA 3 4
DOE 2 2
Process & Product Mapping 3 4
DFSS Quality Function Deployment (QFD) 3 3
Sigmascore 3 3
Function Mapping 3 3
Tools Score 32 36
(*)General Scoring Guidelines:
The candidate must achieve at least the minimum level listed for each tool (a 2 or 3 depending on the tool). In addition, the candidate must demonstrate applications in at
least four of the tools. The selected four tools for application will depend on the project needs and must be approved by the candidate's mentor. If the candidate's business
requires a "project" for certification, the candidate is required to present a Control Plan, which is in addition to the requirement for four tools.

TECHNICAL SCORING KEY

1 Awareness
2 Understands Basic Concepts
3 Understands Concepts & Mechanics
4 Above + Demonstrates One Application

Rev Date: 08-26-10