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Lean Six Sigma Black Belt Course Outline

Course Content and Outline

TotalEstimatedHours: 143.65 *

Course includes choice of software: Minitab® (must purchase separately) or JMP (must purchase separately).

Session 1: Introduction to Lean Six Sigma (4.75 hrs.)

  • Introduction

  • Higher Standards for Higher Performance

  • Input Determines Output

  • Lean Six Sigma Defined

  • What's In a Name?

  • The 5 Lean Principles

  • The 8 Forms of Waste

  • Introduction to EngineRoom® / Minitab® / JMP

  • Success Stories

  • The 99.9% Problem

  • DNA of a Champion


  • Lean Six Sigma Framework


  • DMAIC - The Lean Six Sigma Improvement Process


  • Lean and DMAIC

  • 
Thought Process Mapping - Toolset

  • Organizing for Success


  • Working Relationships
Critical Success Factors

  • 
Exercises and Quiz

  • The Sigma Level



Session 2: Define I – Starting a Project and Leading Teams (6.90 hrs.)

  • Getting Started – Project Initiation

  • Balanced Scorecard Toolset

  • Project Selection Toolset

  • Project Charter Toolset

  • Project Tracking Toolset

  • Fueling The Improvement Engine

  • Leadership Characteristics

  • Practice, Study and Reflection - Learning by Modeling

  • Leading Teams


  • Developing an Effective Team

  • 
Improving Team Development

  • 
Leading Change


  • Leading Change - Continued

  • 
Success Factors For Effective Change Management


  • STakeholder Analysis – RACI Matrix

  • Exercises and Quiz

 

Session 3: Define II - Voice of the Customer (8.20 hrs.)

  • Voice of The Customer

  • Focus on The Customer

  • Understanding Customer Requirements

  • Where to Go For Customer Requirements

  • Conducting Surveys

  • More on Surveys

  • Surveys – Sampling Frame

  • 
Structuring Survey Questions


  • The Degree of Uncertainty in Sampling

  • Guideline for Margin of Error


  • Affinity Diagram Toolset


  • CTQC Tree Diagram Toolset

  • Operational Definition Toolset

  • QFD Toolset

  • Voice Of The Customer As Specifications

  • Exercises and Quiz

 

Session 4: Define III – Mapping the Process (5.25 hrs.)

  • Drawing a Process Picture
  • Process Thinking

  • The Source of Value

  • Value Stream Leverage

  • Process Mapping - Overview

  • Process Mapping (SIPOC)Toolset

  • Flow Charts

  • Value-Added Flow Charts


  • Spaghetti Charts


  • Takt Time

  • 
Value Stream Mapping Toolset

  • 
Define Tollgate – Progress Review

  • Exercises and Quiz

 

Session 5: Measure I – Measurements and Basic Statistics (5.75 hrs.)

  • Measurements and Basic Statistics

  • Business Problem Solving

  • Basic Statistical Terms

  • Descriptive and Inferential Statistics

  • Measurements

  • Discrete vs. Continuous Measurements

  • Measurement Subjects

  • Graphical Summaries

  • Pareto Chart Toolset


  • Histogram Toolset


  • Understanding Variation


  • Measuring Central Tendency

  • 
Quantifying Process Variability

  • The Normal Distribution


  • Exercises and Quiz

 

Session 6: Measure II - Measurement System Analysis (8.55 hrs.)

  • Measurement System Analysis – Introduction

  • Measurement As A Process

  • Cause & Effect Matrix Toolset

  • The Analysis of Measurement Systems

  • The Requirements of Measurement Systems

  • Variable MSA - Gage R & R

  • MSA - Graphing

  • Attribute Measurement System Analysis

  • Calibration of Measurement Systems

  • Collecting Data


  • Developing a Sampling Plan


  • Baseline Performance

  • Derivative Performance Metrics - Throughput Yield

  • Derivative Performance Metrics - Rolled Throughput Yield

  • Calculating the Sigma Level - Toolset

  • Exercises and Quiz

 

Session 7: Measure III - Charting Process Behavior (9.65 hrs.)

  • Introduction – Charting Process Behavior

  • Trend Chart Toolset

  • SPC - Introduction and Background

  • SPC - Introduction to Control Charts

  • SPC - Control Chart Limits

  • SPC - More On Control Limits

  • Implementing SPC

  • SPC Chart Selection

  • Rational Subgrouping Toolset

  • 
X and Moving Range Charts - Toolset

  • Attribute Control Chart Toolset

  • 
X-bar and R Chart Toolset

  • 
Process Capability Toolset


  • The Sigma Level Revisited


  • Measure Tollgate - Progress Review

  • Exercises and Quiz


Session 8: Analyze I – Identifying Potential Root Cause (10.15 hrs.)

  • Analyze I - Introduction

  • Finding The Root Cause

  • Cause & Effect Diagram Toolset

  • Alternative To The Cause & Effect Diagram

  • 5-Why, 1-How

  • A Combination of 5-Why, Pareto, and Trend Charts

  • Box Plots Toolset
Scatter Plot Toolset


  • Correlation and Regression Analysis

  • Multiple Regression Toolset


  • Logistic Regression Toolset


  • Factors In Determining Sample Size

  • Estimating Population Mean


  • Exercises and Quiz


Session 9: Analyze II - Hypothesis Testing (23.15 hrs.)

  • Analyze II - Introduction

  • Introduction to Hypothesis Testing

  • The Process On Trial

  • The Hypothesis - Accept or Reject?

  • Types of Error

  • Power Analysis

  • Power Analysis - Factors

  • Hypothesis Testing

  • Confidence Intervals

  • Treatment Comparisons - Control Charts

  • Comparing One Proportion to a Standard

  • Comparing Two Proportions - Toolset

  • Comparing Multiple Proportions - Chi-Square

  • Comparing One Mean to a Standard - t-test

  • 
Comparing Two Means - t-test Toolset


  • Comparing Multiple Means - ANOVA /F-test Toolset


  • Confidence Intervals - Least Significant Difference


  • Comparing One Variance to a Std. - Chi-Square

  • Comparing Two Variances - F-test Toolset


  • Parametric vs. Nonparametric Tests

  • 
Non Parametric Toolset


  • Hypothesis Testing Learning Lab


  • Exercises and Quiz


Session 10: Analyze III - Design of Experiments (38.55 hrs.)

  • Design of Experiments - Introduction

  • Design of Experiments - History

  • Design of Experiments - Components

  • Design of Experiments - Principles

  • Design of Experiments - Purpose

  • Design of Experiments - Process

  • Design of Experiments – Guidelines

  • Selecting the Right Design

  • Blocking

  • Blocking and Tackling

  • Faster Deliveries Through Experimentation

  • Beyond One-Factor Experiments

 

Session 11: Improve (12.75 hrs.)

  • Improve

  • Design for Six Sigma (DFSS)

  • Benchmarking

  • Brainstorming

  • Narrowing Down The List of Ideas

  • FMEA Toolset

  • Error-proofing

  • Prioritizing and Selecting a Solution

  • The A3 One-Page Report

  • Continuous Flow Toolset

  • Quick Changeover Toolset

  • Cellular Processing Toolset



Session 12: Control (7.00 hrs.)

  • Control

  • Control Charts Revisited

  • The Process Control Plan

  • More On FMEA

  • Visual Control

  • 5-S Approach

  • CHECK Process

  • Total Productive Maintenance

  • Two Level Full Factorial Toolset


  • Two Level Fractional Factorial Toolset

  • General Factorial toolset

  • 
DOE Power and Sample Size


  • Designing An Experiment To Save The Kingdom


  • Better Pizza Through Design of Experiments

  • Designing Experiments to Sell More Coffee

  • Additional Subjects
Analyze Tollgate - Progress Review


  • Design of Experiments Exercises and Quiz

  • Balancing Capacity with Demand


  • The Theory of Constraints (TOC) Toolset

  • Pull System Overview
Pull Scheduling


  • Pull Systems
Core Process Pull Toolset


  • Kaizen Toolset
Corrective Action Matrix


  • Piloting a Solution
System Dynamics Toolset


  • Improve Tollgate – Progress Review


  • Exercises and Quiz

  • TPM Objectives & Benefits


  • TPM Metrics
TPM Core Elements


  • TPM Maintenance Activities


  • Best Practices and Lessons Learned

  • 
Standardized Work - Documenting Process Changes

  • Ending the Project

  • Course Completion

  • Control - Progress Review

  • Exercises and Quiz

  • The Lean Six Sigma Journey