Lean Six Sigma – Black Belt
Lean Six Sigma is a process improvement program that combines two ideas: Lean – a collection of techniques for reducing the time needed to provide products or services, and Six Sigma – a collection of techniques for improving the quality of products and services, substantially contributing to increased customer satisfaction.The Lean Six Sigma Black Belt (BB) is a professional who is well versed in the Lean Six Sigma Methodology who leads improvement projects, typically in a full-time role. A Lean Six Sigma Black Belt possesses a thorough understanding of all aspects within the phases of D-M-A-I-C. They understand how to perform and interpret 6 Sigma black tools and how to use standard principles of Lean.

–          These are the people who are in charge of the Six Sigma projects within their respective companies

–          Most of the time, these are the people who are asked to take on this task on a full time basis. Once the project is completed and everything has been implemented, they will return to their regular duties

–          Along with heading the project, they also are expected to coach, develop and advise other managers so the entire company can achieve this goal

Upon completion of this course, the participant will gain competencies in:

–          The Project Management skills necessary to successfully complete DMAIC projects, including basic knowledge of developing charters, managing stakeholder requirements, planning and estimation techniques, Business Case development, problem solving methods and improvement strategies

–          Demonstrating Return On Investment through successful projects, aiming at reducing the cost of poor quality, increasing process capability, minimizing process cycle time, removing waste and ultimately resulting in increased customer satisfaction

–          Using a blend of theory and practical exercises to ensure that participants have the confidence and capability to deliver more complex business improvement projects and transformations

–          Descriptive and Inferential Statistics techniques, and Data Analysis (graphical and formal) with hands on exercises on real projects data using a variety of software (Excel and MINITAB)

–          Qualitative analysis (process modelling, VOC analysis, Value analysis, Root cause analysis) with formal methods (estimation, hypothesis testing, and correlation analysis)

–          Apply lean principles to determine customer value, determine value streams, understand flow develop pull systems and ensure perfection

–          Control business processes and understand process change (SPC and change management skills)

Pre-requisites –          There are no formal pre-requisites.
Target Audience –          Technical team members, Process improvement team, Support functions, Middle level managers, and Higher level managers
Duration

Certification –          Certificate of attendance-          PMI ® PDUs : 120
Exam (Optional) –          160 hours over 20 days Classroom, divided into 4 months, a week every month
Outline 

 

 

 

 

 

 

Introduction–          Meanings of Six Sigma, General History of Six Sigma & Continuous Improvement, Deliverables of a Lean Six Sigma Project, and Six Sigma Roles & Responsibilities

Define Phase

–          Problem Definition

–          The Problem Solving Strategy Y = f(x), Voice of the Customer, Voice of the Business and Employee, and Voice of the Process

–          Defining a Process, Critical to Quality Characteristics (CTQ’s), Cost of Poor Quality (COPQ), and Pareto Analysis (80:20 rule), and Kano analysis

–          Basic Six Sigma Metrics: a. including DPU, DPMO, FTY, RTY Cycle Time, deriving these metrics and these metrics

–          Stakeholder analysis and mapping, Communications plan, Roles and responsibilities and Facilitation skills

–          Business Case and Probabilistic approaches

Measure Phase

–          Data manipulation

–          Measurement Model and selecting the right metrics

–          Sampling – basic concepts, theory, plan, size and risk

–          Work measurement, determining appropriate business metrics, Cost of Poor Quality

–          Descriptive statistics, and graphical tools (MINITAB ex.)

–          Discrete data measurement and its application

–          Yield and Defects – Process capability measures

–          Statistical concepts and Confidence intervals

–          Process capability

–          Developing a Process Baseline

Analyze Phase

–          Process Value analysis – Value stream mapping

–          Root Cause Analysis – process decomposition, and FMEA

–          Cause and Effect Matrices

–          Exploratory Data Analysis (EDA)

–          Inferential Statistics for Root Cause Analysis

–          Estimation (point estimation and confidence intervals)

–          The Central Limit Theorem (CLT)

–          Hypothesis Testing (Examples and MINITAB Exercises)

–          Hypothesis Testing on Continuous Normal Data (Z and T tests, tests for variances, etc.)

–          ANOVA – Analysis of Variance

–          Tests for discrete variables (proportions, Chi-Square)

–          Correlation Analysis and Correlation indexes (Pearson, Spearman)

–          Regression Analysis overview and exercises

–          Measurement System Analysis (MSA / Gage R&R)

Improve Phase

–          Generating Solution Ideas – Brainstorming (Six Thinking Hats), and Creative Thinking

–          Design of experiments overview, techniques and pitfalls

–          Lean Principles, metrics, Value, and Value Steam Analysis

–          Selecting Improvement Ideas (solution selection matrix)

–          Risk Management – FMEA

–          Pilot Projects

–          Change Management, Kaizen events and 5S Analysis

Control Phase

–          Sustaining improvement, Solution assessment, Benefit realization plans and validation, and Piloting solutions

–          Statistical Process Control (SPC)

–          Control chart theory, creating control charts and specialty control charts (X-bar and R charts, I-MR charts and U Charts)