facebook-logo-webtreatsetctwitter-bird2-webtreatsetclinkedin-logo-webtreatsetc

3 Easy Steps!

  1. Fill out our student survey

  2. Make Payment for Course/Training (we send back registration info)

  3. Follow instructions and begin course/Training

ms-logo-footer2

Lean Six Sigma Black Belt-EngineRoom Course Outline

Course Content and Outline

TotalEstimatedHours: 140.65 *Course includes choice of software: EngineRoom® (included for free), 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 SurveysCourse No. 539 Revised: 2/1/2012

  • 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