Lean Six Sigma Black Belt Training - Signature Series

Topic 1

What is Quality (Introduction)

• Understand the history of quality
• Gathering the voice of the customer
• Garvin's five definitions of quality
• Definitions of quality from quality gurus
• Differences in quality between products and services

Topic 2

Enterprise-wide View (Introduction)

• Understand the history of continuous improvement
• Six Sigma as a Value
• Six Sigma as a Measure
• Six Sigma as a Metric
• Six Sigma Approach
• Six Sigma Process
• Six Sigma System
• Benefits of Six Sigma

Topic 3

Lean (Introduction)

• Understand the history of Lean and the value it brings to an organisation
• The philosophy and goals of Lean Manufacturing
• Understand how Lean integrates with Six Sigma
• Business processes and systems

Topic 4

Leadership (Introduction)

• Leadership responsibilities
• Organisational roadblocks and how to overcome them
• Change management
• Six sigma projects and Kaizen events

Topic 5

Roles and Responsibilities (Introduction)

• Key six sigma players
• Player responsibilities
• Team stages
• Team communication

Topic 6

Six Sigma Important Stakeholders (Define Phase)

• Describe the stakeholders in Six Sigma projects
• Understand how the changeover to Six Sigma implementation affects stakeholders
• Undertake stakeholder analysis

Topic 7

Critical X Requirements (Define Phase)

• Understand the Critical to "X" concept
• Describe categories of performance metrics
• Aligning projects with CTX requirements

Topic 8

Benchmarking (Define Phase)

• Understand the the framework for competitor analysis
• Types of benchmarking
• Steps in benchmarking

Topic 9

Business Performance Measures (Define Phase)

• Balanced scorecard
• Key performance indicators
• Customer loyalty

Topic 10

Financial Measures (Define Phase)

• Understand different financial measures
• Apply net present value calculation (NPV)
• Cost benefit analysis
• Hard and soft financial benefits

Topic 11

Voice of Customer and satisfaction levels (Define Phase)

• Understand the Voice of Customer concept
• Apply procedure to comprehend the VOC
• Questions to identify what is critical to customer satisfaction
• Understand the Kano model
• Juran's customer needs

Topic 12

Critical to Quality Flowdown (Define Phase)

• Understand the definition and purpose of Critical to Quality
• Understand the Critical to Quality steps or flowdown
• Essence of Cost of Poor Quality (COPQ)
• Hard and soft savings

Topic 13

Quality Function Deployment (Define Phase)

• Brief history of QFD
• Questions answered using QFD
• House of quality
• Building the House of Quality

Topic 14

Performance Metrics (Define Phase)

• Explain what performance metrics are and they can be used to measure the effectiveness and efficiency of a process and establish goals for a project’s anticipated outcome
• Explain the difference between process and business metrics
• Know what questions to ask to determine the quality of the performance metrics

Topic 15

Project Charter (Define Phase)

• Understand the purpose of a project charter
• Understand the requirements and the elements of a project charter
• Know how to phrase a problem statement
• Know what questions to ask to determine the quality of the performance metrics

Topic 16

Project Management and Tracking (Define Phase)

• Creation of a project baseline
• Project tracking
• Determine the reason for experimenting
• Structure and characteristics of Work Breakdown Structure (WBS)
• Purpose and examples on Gantt Chart

Topic 17

Wrap Up & Action Items (Define Phase)

Topic 18

Processes and Process Characteristics (Measure Phase)

LSS Black Belt Measure Phase - The Measure Phase of the DMAIC methodology is constructed to introduce important Lean Six Sigma tools for characterising your business issues.

• Define a process
• Explain different types of processes
• Explain different process characteristics

Topic 19

Process Maps and Flow Chart (Measure Phase)

• Understand how to create a process map
• Understand the different types of process maps
• Describe process flow metrics and how they are used

Topic 20

SIPOC (Measure Phase)

• Understand meaning and importance of SIPOC diagram
• Understand when to use SIPOC
• Create a SIPOC diagram

Topic 21

Data Types and Measurement Scales (Measure Phase)

• Understand how to choose different data collection methods
• Know how to use check sheets and when to use different types of check sheets
• Understand the advantages and disadvantages of automated gauging
• Know how to code data and the advantages and disadvantages of coding data
• Understand the concepts of data integrity and accuracy

Topic 22

Data Collection (Measure Phase)

• Understand how to choose different data collection methods
• Know how to use check sheets and when to use different types of check sheets
• Understand the advantages and disadvantages of automated gauging
• Know how to code data and the advantages and disadvantages of coding data
• Understand the concepts of data integrity and accuracy

Topic 23

Sampling Strategies (Measure Phase)

• Understand the concept of sampling and the different types of sampling strategies
• Apply probability sampling strategies
• Apply non-probability sampling strategies
• Know how to calculate and determine sample size for continuous and discrete data

Topic 24

Fishbone Diagram (Measure Phase)

• Understand the purpose and meaning of the Ishikawa or Fishbone diagram
• Apply the Fishbone diagram
• Apply non-probability sampling strategies
• Know how to calculate and determine sample size for continuous and discrete data

Topic 25

Relational Matrix /Prioritisation Matrix (Measure Phase)

• Understand that a relational matrix is a tool used to measure which of the input variables has the greatest effect on output
• Know when and how to use a relational matrix
• Understand the differences between the X-T matrix and the Quality Function Deployment (QFD)

Topic 26

Basic Statistics (Measure Phase Module)

• Explain the various statistics used to express location and spread of data
• Describe the characteristics of a Normal Distribution
• Explain the measures of dispersion
• Understand and use measures of symmetry
• Explain the Central Limit Theory
• Explain frequency distribution

Topic 27

Graphical Methods (Measure Phase)

• Understand how to construct histograms and differences in distribution shape
• Construct a histogram using Minitab
• Construct a stem and leaf plot
• Construct a box plot
• Construct a run chart
• Explain the significance of P values in relation to hypotheses
• Compare graphical methods and decide which is best to use

Topic 28

Inferential Statistics (Measure Phase)

• Steps involved in analytical statistics
• The Rules of Probability
• Combinations and Permutations in probability
• Probability distribution
• Discrete and continuous distributions

Topic 29

Gauge R and R (Measure Phase)

• Understand the concept of gauge repeatability and reproducibility
• Understand the concepts of accuracy, precision, linearity, stability and bias
• Apply Gauge R and R
• Apply Gauge R and R regression analysis

Topic 30

Process Capability Analysis (Measure Phase)

• Understand causes of variation
• Estimate Capability for Continuous Data
• Describe the impact of Non-normal Data on the analysis presented in this module for Continuous Capability
• Estimate Capability for Attribute Data

Topic 31

Wrap Up & Action Items (Measure Phase)

Topic 32

Graph and Data Analysis (Analyse Phase)

• Construct a scatter diagram
• Understand correlation and regression analysis
• Apply the method of least square
• Apply a simple linear regression model
• Apply multiple linear regression analysis

Topic 33

Multi-Vari Analysis (Analyse Phase)

• Perform a Multi-Vari Analysis
• Interpret and a Multi-Vari Graph
• Identify when a Multi-Vari Analysis is applicable

Topic 34

Intro to Hypothesis Testing (Analyse Phase)

• Articulate the purpose of Hypothesis Testing
• Explain the concepts of the Central Tendency
• Be familiar with the types of Hypothesis Tests
• Statistical inference
• Understand the concepts between statistical and practical significance
• Calculate point and interval estimations
• Calculate margin of error and sample size
• Calculate confidence intervals

Topic 35

Hypothesis Testing Normal Data (Analyse Phase)

• Determine appropriate sample sizes for testing Means
• Conduct various Hypothesis Tests for Means
• Properly Analyse Results
• Be able to conduct Hypothesis Testing of Variances
• Understand how to Analyse Hypothesis Testing Results

Topic 36

Hypothesis Testing Non-Normal Data (Analyse Phase )

• Conduct Hypothesis Testing for equal variance
• Conduct Hypothesis Testing for Medians
• Analyse and interpret the results
• Calculate and explain test for proportions
• Calculate and explain contingency tests

Topic 37

Pareto Charts (Analyse Phase)

• Explain the objectives of a Pareto chart
• Construct a Pareto chart
• Test proportion = specified value
• Test if two proportions are equal

Topic 38

Failure Mode and Effects Analysis (Analyse Phase)

• Explain the of conducting FMEA and its various elements
• Explain and calculate Risk Priority Number
• Understand procedures involved in conducting FMEA
• Understand differences of design and process FMEA
• Explain advantages and disadvantages of conducting FMEA

Topic 39

Non-Value Added Activities (Analyse Phase)

• Understand the seven types of process waste
• Understand the difference between value and non-value added activities
• Identify non-value added activities from process maps

Topic 40

Value Stream Mapping (Analyse Phase)

• Understand VSM process and symbols used
• Create a Value Stream Map
• Understand the difference between cycle time and takt time
• Know when to use Lean Systems
• Construct a spaghetti chart
• Outline the benefits of VSM

Topic 41

Wrap Up & Action Items (Analyse Phase)

Topic 42

Generate New and Re-usedSolutions (Improve Phase)

LSS Black Belt Improve Phase - The Improve Phase of the DMAIC methodology is constructed to introduce important Lean Six Sigma tools for properly controlling solutions.

• Generate solution ideas
• Apply six thinking hats to evaluate solutions
• Understand the role of bench-marking solutions
• Understand the concept of process entitlement

Topic 43

5S (Improve Phase)

• Understand the 5 concepts in the 5S model
• Understand the effect of 5S on improvements

Topic 44

Evaluate and select top solution (Improvement Phase)

• Understand the approach to design and implement a solution
• Prepare process maps that reflect the desired state
• Understand the concept of poka-yoke (mistake proofing)
• Understand the steps to pilot the top solution

Topic 45

Designing Experiments (Improve Phase)

• Understand the concept of experiment design and the terminology
• Nomenclature for factorial experiments
• Understand different types of design
• Understand the difference between balanced and orthogonal designs and the role of centre points
• Conduct two-way ANOVA experiments with and without replicas
• Analyse factorial experiments
• Create a Full and a Fractional Factorial Design

Topic 46

Kaizen and Kanban and Theory of Constraints (Improvement Phase)

• Understand the concept of Kaizen and Demming cycle and a Kaizen event
• Understand the concept of Kanban and the Push vs Pull system of production
• Know how to create strategic buffer
• Understand the Theory of Constraints and the five focusing steps

Topic 47

Single Minute Exchange of Die (Improve Phase)

• Understand the objectives of SMED
• Understand the techniques of implementing and the effects of SMED

Topic 48

Risk Analysis and Mitigation (Improve Phase)

• Understand the purpose of a risk assessment tool
• Understand how to conduct a SWOT and PEST analysis
• Understand the concept of poka-yoke (mistake proofing)
• Understand the steps to pilot the top solution

Topic 49

Total Productive Maintenance (Improve Phase)

• Explain the concept of TPM
• Understand the 8 pillars of TPM
• Explain the benefits of TPM

Topic 50

Lean Six Sigma Logistics (Improve Phase)

• Understand how Lean Six Sigma techniques can be used to optimise the performance of an organisation’s logistics network
• Know how to implement Lean Logistics and how they can reduce inventory maintenance costs

Topic 51

Wrap Up & Action Items (Improve Phase)

Topic 52

Statistical Process Control - SPC (Control Phase )

• Describe the elements of an SPC Chart and the purposes of SPC
• Understand how SPC ranks in defect prevention
• Describe the special cause detection rules
• Design subgroups if needed for SPC usage
• Understand the differences between Attribute and Continuous Control Charts
• Create an I-MR control chart
• Create an X-bar R chart
• Create an X-bar S chart
• Create P and Np charts
• Create a U chart
• Create time-weighted charts
• Explain the purpose of a Visual Factory

Topic 53

Maintain Controls (Control Phase)

• Understand the purpose of conducting a cost benefit analysis
• Understand the purpose of a Control Plan
• Understand the purpose of a documentation plan
• Understand the concept of lessons learned

Topic 54

Wrap Up & Action Items (Control Phase)