Lean Manufacturing Yellow Belt
A shop-floor Lean programme for production, maintenance and planning teams. Participants learn core Lean principles, run a Kaizen project using an A3 charter, and apply 6S, visual management, cell design, quick changeover, poka-yoke and pull systems, with videos and simulation to reinforce each tool.
At a glance
- 5 days
Who it's for
- Production, maintenance and planning teams; quality control; process supervisors
Learning objectives
- Apply core Lean tools on the shop floor
- Run a Kaizen project using an A3/charter
- Identify and remove waste
Detailed content
- Value to customer; what is Lean; push vs pull
- TPS & Kaizen; Lean principles; Lean in design
- Lean benefits; internal/external customers; quality costs
- Kaizen events and projects; Kata; A3 reporting
- Problem identification & analysis; Gemba
- Brainstorming, cause & effect, Pareto, scatter, process maps
- Idea management, opportunity search, spaghetti diagram
- 6S & visual management
- Cell design; quick changeover (SMED); poka-yoke
- TPM overview; JIT & pull (Nissan case)
- Project charter; current-state VSM review
- Change management; VOC; key success factors
- Sustaining the improvement; Yellow Belt criteria
Day-by-day agenda
A typical schedule. In-company versions are tailored to your processes, data and timing.
- Lean Foundations
- Improvement Methods
- Lean Tools
- Project & Sustainment
- Practical workshop applying the tools to participants' cases
- Mock exam, review of weak areas and exam strategy
Practice, tools and assessment
Hands-on practice
- Catapult or paper-helicopter simulation run through all DMAIC phases
- Write a project charter and SIPOC for a real process from your workplace
- Analyse a real data set in Minitab/Excel: capability, hypothesis tests and regression
- Waste walk (gemba) using the 8-waste checklist
Tools and templates you keep
- Project charter and SIPOC templates
- DMAIC tollgate checklist
- Control plan and response plan template
- 8-waste observation sheet
How learning is assessed
- Written exam at the end of the course
- Improvement project reviewed at DMAIC tollgates (where required)
Built on these standards and bodies of knowledge
- ASQ Six Sigma Body of Knowledge
- IASSC Lean Six Sigma Body of Knowledge
- ISO 13053-1/-2 (Six Sigma quantitative methods)
How it is delivered
- Public courses in Cairo, in-company programs and live online training
- Practical exercises, case studies and examples from your sector
- Can also run as Train & Stay in Sharm El Sheikh, Hurghada or Cairo
Part of these career paths
- Operational Excellence & Lean Six Sigma · Practitioner
What participants say
“When I started the course I was a quality specialist; after it I was promoted to quality team leader. Six Sigma changed a lot for me. Very comprehensive – I'd suggest it 100%.”
“The course teaches you to take hold of a problem logically and solve it scientifically. The explanation was simple, and this way of thinking matters for life as a whole.”
“What I gained most: I never imagined how much money projects can lose. We ran a small cost project on our site and found mistakes we can now avoid.”
Frequently asked questions
How long is Lean Manufacturing Yellow Belt?
The program runs 5 days. In-company versions can be adapted to your needs.
Is the course taught in Arabic or English?
Sessions are usually delivered in Arabic with English technical terms and materials. Full English delivery is available for in-company groups.
Can you run it inside our company?
Yes. In-company programs use exercises built on your own processes. Tell us the group size and preferred timing and we will send a proposal.
Will I receive a certificate?
Participants who complete the program and its assessment receive a certificate from The Excellence Center, which can be verified online.
More programs in this field
- Applied Statistics for Six Sigma3 days
- Foundations of Operational Excellence3 days
- Lean Six Sigma Black Belt20–25 days
- Lean Six Sigma Champion (Sector Managers & Directors)2 days
- Lean Six Sigma Green Belt9–10 days
- Lean Six Sigma Master Black Belt10 days
- Lean Six Sigma Orange Belt5 days
- Lean Six Sigma White Belt (Awareness)1 day
- Lean Six Sigma with Value Stream Mapping (5-day practitioner / 12-day Green Belt track)5 days
Get dates, fees and the full outline.
Tell us whether you are joining as an individual or planning a program for your team.