Online Lean Six Sigma Black Belt Training

Objectives:

The learning objective of the Lean Six Sigma Black Belt course is to develop a comprehensive set of skills that will allow you to function effectively as a Lean Six Sigma Black Belt. The Lean Six Sigma Black Belt body of knowledge includes techniques for both quantitative and non-quantitative analysis, as well as the team leadership skills necessary to get projects across the goal line. 

After completing this course, you should be able to DO the following:

• Communicate using Lean & Six Sigma concepts.

• Think about your organization as a collection of processes, with inputs that determine the output.

• Relate Lean Six Sigma concepts to the overall business mission and objectives.

• Use the concept of a Sigma Level to evaluate the capability of a process or organization.

• Understand and apply the five step D-M-A-I-C model as a framework to organize process improvement activity.

• Employ a wide range of process improvement techniques, including Design of Experiments, within the D-M-A-I-C model.

• Recognize the organizational factors that are necessary groundwork for a successful Six Sigma effort.

• Employ your Six Sigma skills to lead a successful process improvement project delivering meaningful results to the organization.

Course Content and Outline

Total Estimated Hours: 141.3

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

• Introduction

• Higher Standards for Higher Performance

• Input Determines Output

• Six Sigma Defined

• What's In a Name?

• Success Stories

• The Sigma Level

• The 99.9% Problem

• Calculating the Sigma Level - Toolset

• DNA of a Champion

• Six Sigma Framework

• DMAIC - The Six Sigma Improvement Process

• Lean and DMAIC

• Thought Process Mapping - Toolset

• Organizing for Success

• Working Relationships

• Critical Success Factors

• Exercises and Quiz

Session 2: Define 1 - The Value Stream (9.35 hrs.)

• Define - Introduction

• Process Thinking

• The Source of Value

• Value Stream Leverage

• Process Mapping - Overview

• Process Mapping (SIPOC)Toolset

• Flow Charts

• Value-Added Flow Charts

• Spaghetti Charts

• Value Stream Mapping Toolset

• Introduction to Minitab

• Pareto Chart Toolset

• Balanced Scorecard Toolset

• Project Selection Toolset

• Project Charter Toolset

• Project Tracking Toolset

• Stakeholder Analysis - RACI Matrix

• Exercises and Quiz

Session 3: Define 2 - Voice of the Customer (8.95 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

• Voice Of The Customer As Specifications

• QFD Toolset

• Define - Progress Review

• Exercises and Quiz

Session 4: Measure 1 - Introduction to Measurement (9.9 hrs.)

• Measure

• Measurements

• Discrete vs Continuous Measurements

• Measurement Subjects

• Measurement As A Process

• Cause & Effect Matrix Toolset

• The Analysis of Measurement Systems

• The Requirements of Measurement Systems

• 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

• The Sigma Level Revisited

• Exercises and Quiz

Session 5: Measure 2 - Charting Process Behavior (12.4 hrs.)

• Introduction - Measure II

• Trend Chart Toolset

• Histogram Toolset

• Quantifying Process Variability

• 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

• Related Theory

• Process Capability Toolset

• Measure - Progress Review

• Exercises and Quiz

Session 6: Analyze 1 - Identifying Root Cause (10.65 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

• 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 7: Analyze 2 - Hypothesis Testing (23.85 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 - Z-test 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

• Hypothesis Testing Learning Lab

• Exercises and Quiz

Session 8: Analyze 3 - Design of Experiments (39.65 hrs.)

• Design of Experiments - Introduction

• Design of Experiments

• Design of Experiments - Components

• Design of Experiments - Principles

• Design of Experiments - Purpose

• Design of Experiments - Process

• Design of Experiments - Guidelines

• Blocking

• Blocking and Tackling

• Faster Deliveries Through Experimentation

• Beyond One-Factor Experiments

• Two Level Full Factorial Toolset

• Two Level Fractional Factorial Toolset

• Designing An Experiment To Save The Kingdom

• Better Pizza Through Design of Experiments

• Brewing Better Beer Using DOE

• Additional Subjects

• Analyze - Progress Review

• Design of Experiments Exercises and Quiz

Session 9: Improve (10.7 hrs.)

• Improve

• Design for Six Sigma (DFSS)

• Benchmarking

• Brainstorming

• Narrowing Down The List of Ideas

• FMEA Toolset

• Error-proofing

• Prioritizing and Selecting a Solution

• Continuous Flow Toolset

• Quick Changeover Toolset

• Pull Scheduling

• Corrective Action Matrix

• Piloting a Solution

• System Dynamics

• Characteristics of Dynamic Systems

• System Dynamics Examples

• Another System Dynamics Example

• System Dynamics Application

• System Dynamics Summary

• Improve - Progress Review

• Exercises and Quiz

Session 10: Control (6.85 hrs.)

• Control

• More On SPC

• The Process Control Plan

• More On FMEA

• Visual Control

• 5-S Approach

• CHECK Process

• Total Productive Maintenance

• TPM Objectives & Benefits

• TPM Metrics

• TPM Core Elements

• TPM Maintenance Activities

• Best Practices and Lessons Learned

• Documenting Process Changes

• Ending the Project

• Control - Progress Review

• Exercises and Quiz

Session 11: Leading Teams and Leading Change (4.25 hrs.)

• Leadership Introduction

• 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

       • Exercises and Quiz