Course Summary

Crafting great beer is only part of the equation for brewery success. Sustaining your operation also requires smart, efficient, and problem-free processes to:

• Solve recurring problems faster—and for good
• Boost product quality and consistency
• Reduce waste and downtime
• Improve your bottom line

This practical, engaging virtual course is designed specifically for brewers, packaging teams, cellar staff, quality professionals, and operations leaders in the brewing industry. It introduces the core principles of Continuous Improvement (CI) using Lean and Six Sigma methodologies with real-world applications tailored to brewery environments.

From reducing process variation and eliminating waste to improving quality and throughput, this course provides the practical tools and frameworks you need to optimize brewing operations while maintaining product integrity and meeting customer expectations.

Explore proven frameworks like PDCA (Plan-Do-Check-Act), DMAIC (Define, Measure, Analyze, Improve and Control), the 5 Whys, and Fishbone diagrams to uncover root causes, standardize solutions, and build a culture of efficiency and accountability.

Learning Objectives

By completing this course, you will:

• Develop a solid understanding of Lean Six Sigma concepts, tools, and methodologies.
• Acquire the skills to apply problem-solving techniques effectively within your production environments.
• Gain confidence to implement purposeful and sustainable improvements in your work processes.

Course Format & Completion Requirements

This course will take place via virtual recorded lessons with a capstone assignment and live final session where attendance will be required for course completion. There will be a community discussion board accessible by participants, and quizzes to follow each lesson.

To earn a completion certificate, participants will need to:

1. View the recorded lessons for each module.
2. Access and contribute to the weekly discussion forum.
3. Successfully complete the quiz associated with each module.
4. Complete the capstone assignment.
5. Join and participate in the final live session.
   

Tuition

• Course Outline and Schedule

  Course Outline and Schedule

  *Denotes a requirement for course completion.

  
  

  1. Course Welcome (How to use the Learning System)

     1. Course Navigation & Completion Requirements
     2. Getting Help
     3. Course Syllabus
     4. LIVE SESSION - Course Introduction: September 30, Time TBD
        • Introduction of Instructor, Content and Course Expectations

  2. Module 1: Overview of Concepts & Core Principles

     1. Recorded Lesson: Released September 30*
     2. Supplemental Materials: Slide deck pdf
     3. Community Discussion Forum: Participation*
     4. Knowledge Check/Module Quiz*
     5. Learning Targets:
        1. Become familiar with Lean and Six Sigma methodologies
        2. Understand the core principles of Continuous Improvement (CI)
        3. Recognize when to use structured problem-solving methods and tools
     6. Content:
        1. Overview of Lean and Six Sigma
           1. History
           2. Importance of Company Culture
           3. Lean manufacturing
           4. Six Sigma bell curve
           5. Six Sigma belt descriptions
           6. PDCA (Plan-Do-Check-Act) cycle
           7. SIPOC
           8. Value Stream Mapping
           9. DMAIC
           10. TQM
        2. Core Principles of Kaizen (Continuous Improvement)
           1. Customer-Focused
              1. ISO Standards
           2. Data Collection and Analysis
              1. Record Keeping
              2. KPI's
              3. Trend Analysis
           3. Reducing Process Variation
              1. Standardized work
              2. Mistake-Proofing (Poke Yoke)
              3. Waste Identification and elimination
              4. 5S
           4. Identifying and Eliminating Waste
           5. Change Management
           6. Problem Solving
        3. Problem Solving Methods and Tools
           1. Tier I Tools
              1. PDCA
              2. Defining the Problem (5W1H)
              3. Pareto
              4. 5-Why
           2. Tier II Tools
              1. DMAIC
              2. Fishbone
              3. RCA
              4. FMEA

  3. Module 2: Reducing Variation & Eliminating Waste

     1. Recorded Lesson: Released October 7*
     2. Supplemental Materials: Slide deck pdf
     3. Community Discussion Forum: Participation*
     4. Knowledge Check/Module Quiz*
     5. Learning Targets:
        1. Understand the importance of standardization
        2. Grasp the definition of 5S and its importance
        3. Become familiar with the types of process waste and how to eliminate them
     6. Content:
        1. Process Standardization
           1. Standard Work and Meeting Structure
           2. Equipment Settings
           3. Document Control – Policies, SOPs, WI’s, OPL’s
        2. Reducing Variation
           1. Mistake-Proofing (Poke Yoke)
           2. 5S Method
           3. What is the data telling us?
              1. KPI's
              2. SPC
           4. Understanding and eliminating waste
              1. 8 (10*) Types of Waste
              2. Tools to eliminate them
                 1. Spaghetti diagram
                 2. VSM
                 3. Personnel development

  4. Module 3: Problem Solving Methods & Tools

     1. Recorded Lesson: Released October 14*
     2. Supplemental Materials: Slide deck pdf
     3. Community Discussion Forum: Participation*
     4. Knowledge Check/Module Quiz*
     5. Learning Targets:
        1. Understand when to implement structured problem-solving
        2. Become familiar with problem-solving tools
        3. Adapt problem solving methods and tools to your production environment
     6. Content:
        1. Structured problem solving – when and how to use it
           1. Failure triggers
           2. Group approach
           3. Defining the problem
           4. Solution Prioritization
        2. Problem Solving Tools with Examples
           1. Tier I Tools
              1. PDCA
              2. Defining the Problem (5W1H)
              3. Pareto
              4. 5-Why
           2. Tier II Tools
              1. DMAIC
              2. Fishbone
              3. RCA
              4. FMEA

  5. Module 4: Capstone & Course Completion

     1. Capstone Assignment: Released October 21, Due October 28*
     2. Live Final Session: October 28, Time TBD
     3. Learning Targets:
        1. Be able to apply one of the learning tools to a current problem within your brewery.
        2. Discuss the learned tool, problem-solving techniques, and results with fellow participants.
        3. Bring any questions for the course instructor.