Lean Six Sigma Black Belt

Lean Six Sigma Black Belt Certification Training course Outline

Lean

• Lean history
• Waste & spaghetti chart
• Lean Culture
• Lean house
• Lean Principles
  • Specify Value
  • Identify the value stream
  • Flow
  • Pull
• Perfection
• Mura & muri
• Kaizen

 

 Six sigma

• Why is six sigma
• Six sigma history
• What is six sigma
• Six sigma levels
• Six sigma methodology
• Roles & responsibilities
• Case study

 

Define Phase

• Define Problem
• Who is the customer?
• VOC (Voice of customer)
• CTQ (Critical to quality)
• Workshop 1 (Process map)
• Workshop 2 ( process requirements)
• Workshop 3 ( Process Improvement)18
• Select project problem.
• Select Process
• process map.
• Workshop
• Define Project metrics
• DPU
• FTY
• RTY
• COPQ
• Identify stakeholders
• Quality Tool >> SIPOC
• Workshop
• Power Interest Matrix
• Workshop
• Project charter
• Workshop

 

Measure Phase

• Process Discovery (Define all Possible Xs )
• Affinity Diagram
• Workshop
• Fishbone Analysis
• Workshop
• Process Mapping (LEVEL 2)
• Value stream mapping
• Workshop
• Select Vital few (Xs)
• X-Y Matrix.
• Failure mode and effect analysis (FMEA)
• Workshop
• Pareto
• Six sigma Statistic (How your processes speak to you?)
• Statistical Notation
• Data types
• Descriptive Statistics (Minitab)
• Normal Distribution
• None-Normal Distribution
• Normality test (Minitab)
• Graphing – Histogram (Minitab)
• Graphing – Dot Plot (Minitab)
• Graphing – Box Plot (Minitab)
• Graphing – Time series Plot (Minitab)
• Prepare data Collection plan
• Workshop

 

Validating measurement system (MSA).

• Introduction
• Sources of Variation
• Accuracy VS Precision
• Accuracy Errors
• Precision Errors
• Measurement errors
• MSA Minitab Methods
• Gage R&R Crossed (Minitab)
• Gage R&R – Attribute MSA (Minitab)
• Execute data collection plan.
• Measure process capability & sigma level.
• Process Capability
• Process Behavior
• Problem Solving Options
• Measure process capability & sigma level.
• Capability Analysis
• Short term VS Long term study
• Process long term shifting
• Measures of Capability (Minitab)
• Capability Formula
• Capability Steps
• Attribute Capability Steps
• Z Score
• Attribute Capability Example

 

 Analyze Phase

• Introduction
• Inferential statistic
  • Central limit theorem (Minitab)
  • Sampling (Minitab)
  • Classes of data Distributions-
• Analyze Data (to find sources of variation)
  • Mukti-Vari study (Minitab)
• Analysis of Process & Identify root causes
• Hypothesis testing (Verify root causes )
  • Hypothesis test (Normal data)
    • Mean – 1-sample t test (Minitab)
    • Mean – 2-sample t test (Minitab)
    • Mean – Paired t test (Minitab)
    • Mean – one way anova (Minitab)
    • Variance – 1 sample variance (Minitab)
    • Variance – (test of equal Variance) (Minitab)
  • Hypothesis test (Non Normal )
    • Variance –(Test of Equal Variance) (Minitab)
    • Median – 1 sample Sign Test (Minitab)
    • Median – 1 sample Wilcoxon (Minitab)
    • Median – 2 samples – Mann-Whitney (Minitab)
    • Median – >2 samples – Mood’s Median Test
  • (Minitab)
    • Median – >2 samples – Kruskal-Wallis test
  • (Minitab)
  • Hypothesis test (Non-Normal) attribute
    • 1-sample Proportion (Minitab)
    • 2-sample Proportion (Minitab)
    • more than 2-sample Proportion (Minitab)
  • Process modeling and regression
    • Correlation (Minitab)
    • Regression
      • Simple Regression (Minitab)
      • Data transformation (Minitab)
      • Multiple Linear Regression (Minitab)

 

• • • DOE
    • Introduction
    • DOE Steps
    • Good Experiment Requirements
    • Terminology
    • Principles of an Experimental Design
    • Important questions.
    • Experimental Objectives.
    • DOE types in Minitab
    • Screening
    • Definitive screening Designs
    • Plackett-Burman Designs
    • Fractional
      • 2 factorial design
    • Full factorial design
    • Fractional Factorial or Full Factorial
    • The Confounding effect.
    • Resolution
    • Full factorial Example
    • Response surface
    • Types of design
    • Central composite design
    • Box-Behnken Design
    • Custom Design
    • Mixture
    • What is a mixture design
    • Example : make 1 liter of tea
    • Mixture Designs
    • Simplex Lattic design
    • Simplex Centroid Design
    • Extreme vertices design
    • Taguchi
    • Concept
    • Achieving Design Robustness
    • Taguchi Designs

 

Improve

• Brainstorming to create solutions.
• Visual management VM
• Kanban System
• Poka Yoke
• Testing the solutions and Select the best solution.
• Ideas Prioritization
• Cost Benefit Analysis
• Pareto priority index
• FMEA Workshop ( Discussed before)
• Design of experiments (DOE)
• Implement the solution (Action plan).

 

 Control

• Control the process
• Standardization of process
• RACI Matrix
• Control plan
• Statistical Process Control SPC
• Control charts minitab
• Project Closing
• Project summary
• Project benefits

 

 
Advanced practices

Lean Six Sigma Black Belt Certification Training course Objectives

• Understand the basic function of y=f(x)
• Basic understanding of Identifying where variances are occurring in a function.
• Have an understanding of the other process improvement methodologies and how they differ from Six Sigma.
• Understand Six Sigma philosophies and how to recognize opportunity.
• Understand how to frame quality into what is important to the customer.
• Understands the “how and why” regarding a company launching a quality improvement initiative like Six Sigma.
• Understand how team are formed and the role of each belt
• level within the Six Sigma project.
• Understand and define DMAIC
• Understand why the DMAIC process is utilized.
• Understand why continual communication is critical to the success of the project.
• Understand the critical role that a Yellow Belt, or “Subject Matter Expert” plays within the Six Sigma team.
• Determine how to define a process. Process owners, scope and boundaries.
• Understand Critical to Quality (CTQ) measures.
• Understand the Sigma level, RTY, DPU, DPMO, FPY. Consequential metrics, Quality Metrics, Cost Metrics, Scheduling Metrics.
• Understand the cost of poor quality.
• Understand the process to estimate the baseline.
• The Project Definition and scoping of goals and objectives are discussed, how the process is defined in terms of stakeholders, and the functionalities of the process.
• Getting more detail into the process, what metrics and measurements are involved as well as estimating the baseline of the current “as is” process.
• Learn to create a project charter and build the business case.
• Gain an understanding of Six Sigma Statistics.
• Have a basic understanding of Measurement Systems Analysis. This includes Gage R&R, Bias Linearity, & Stability.
• Have a basic understanding of process capability. System design, Parameter design, and tolerances.
• Have a basic understanding of statistical theories which involve inference.
• Have a basic understanding of Hypothesis Testing.
• Have a basic understanding of regression analysis.
• Have a basic understanding of design of experiments and factorial experiments.
• Have a basic understanding of design of control tools and statistical process control tool usage.
• Understand when and how to end a Six Sigma project.
• Understand change management principles. Understand the Black Belt role in facilitating change.
• Have an understanding of Project Management and the role it plays in Six Sigma for a Black Belt.

• Engineers / Professionals / Executives who want to understand Six Sigma as a management tool for process and performance improvement at their work place.
• Managers, Project Leaders, Senior Engineers, Black Belt Candidates and anyone who desires an understanding of Six Sigma principles and skills.
• Also production managers, front line supervisors, quality professionals, and individuals who are responsible for improving quality and processes at an enterprise or departmental level, including champions and process owners.