Lean Six Sigma Black Belt
IASSC Certified
12 Days Program
4 hours exam – 150 MCQ & True/False Questions
80% to Pass Exam
Course Outline
Day 1
Define Phase
- The Basics of Six Sigma
o Meanings of Six Sigma
o General History of Six Sigma & Continuous Improvement
o Deliverables of a Lean Six Sigma Project
o The Problem Solving Strategy Y = f(x)
o Voice of the Customer, Business and Employee
o Six Sigma Roles & Responsibilities
- The Fundamentals of Six Sigma
o Defining a Process
o Critical to Quality Characteristics (CTQ’s)
o Cost of Poor Quality (COPQ)
o Pareto Analysis (80:20 rule)
o Basic Six Sigma Metrics
- Selecting Lean Six Sigma Projects
o Building a Business Case & Project Charter
o Developing Project Metrics
o Financial Evaluation & Benefits Capture
- Strategies of Implementing Lean and Six Sigma in an
organization
o Difference and Similarities between Lean and Six Sigma
o An example of implementing Six Sigma for the whole
enterprise.
o Other Models of Implementing Six Sigma
- Lean and Six Sigma Implementation Case Study
- Project Charter Case Study
Day 2, 3 & 4
Measure Phase
- Process Definition
o Cause & Effect / Fishbone Diagrams
o Process Mapping, SIPOC, Value Stream Map
o X-Y Diagram
o Failure Modes & Effects Analysis (FMEA)
- Introduction to Minitab
- Six Sigma Statistics
o Basic Statistics
o Descriptive Statistics
o Normal Distributions & Normality
o Graphical Analysis
- Measurement System Analysis
o Precision & Accuracy
o Bias, Linearity & Stability
o Gage Repeatability & Reproducibility
o Variable & Attribute MSA
- Process Capability
o Capability Analysis
o Concept of Stability
o Attribute & Discrete Capability
o Monitoring Techniques
- Measurement System Analysis Case Study
- Micro Process Map Case Study
Day 5, 6 & 7
-
Analyze Phase
- Patterns of Variation
o Multi-Vari Analysis
o Classes of Distributions
- Inferential Statistics
o Understanding Inference
o Sampling Techniques & Uses
o Central Limit Theorem
- Hypothesis Testing
o General Concepts & Goals of Hypothesis Testing
o Significance; Practical vs. Statistical
o Risk; Alpha & Beta
o Types of Hypothesis Test
- Hypothesis Testing with Normal Data
o 1 & 2 sample t-tests
o 1 sample variance
o One Way ANOVA
o Tests of Equal Variance, Normality Testing and Sample
Size calculation performing tests and interpreting results.
- Hypothesis Testing with Non-Normal Data
o Mood’s Median
o Mann-Whitney
o Kruskal-Wallis
o Friedman
o 1 Sample Sign
o 1 Sample Wilcoxon
o One and Two Sample Proportion
o Chi-Squared (Contingency Tables)
Day 8, 9 & 10
-
Improve Phase
- Simple Linear Regression
o Correlation
o Regression Equations
o Residuals Analysis
- Multiple Regression Analysis
o Non- Linear Regression
o Multiple Linear Regression
o Confidence & Prediction Intervals
o Residuals Analysis
- Designed Experiments
o Experiment Objectives
o Experimental Methods
o Experiment Design Considerations
- Full Factorial Experiments
o 2k Full Factorial Designs
o Linear & Quadratic Mathematical Models
o Balanced & Orthogonal Designs
o Fit, Diagnose Model and Center Points
- Fractional Factorial Experiments
o Designs
o Confounding Effects
o Experimental Resolution
Day 11 & 12
-
Control Phase
- Lean Enterprise
o Understanding Lean
o The History of Lean
o Lean and Six Sigma
o The Seven Elements of Waste
o 5S
o Poka-Yoke (Mistake Proofing)
- Statistical Process Control (SPC)
o Data Collection for SPC
o I-MR Chart
o Xbar-R Chart
o U Chart
o P Chart
o NP Chart
o X-S chart
o CumSum Chart
o Control Methods
o Control Chart Anatomy
o Subgroups, Impact of Variation, Frequency of Sampling
o Center Line & Control Limit Calculations
- Six Sigma Control Plans
o Cost Benefit Analysis
o Elements of the Control Plan
o Elements of the Response Plan
FAQ
What are the course objectives?
-
- • Learn the basic definitions and terminologies of Lean Six Sigma System.
- • Able to visualize how Lean Six Sigma is deployed within an organization and understand why it’s a proven methodology that helps to save cost while improving quality and sustaining the success.
- • Learn the five phases of a Lean Six Sigma initiative: Define Phase, Measure Phase, Analyze Phase, Improve Phase and the Control Phase.
- • Exposed to a case study of a real Lean Six Sigma project to assist in visualizing the Define, Measure, Analyze, Improve and Control phases of a project.
- • Learn how to use Minitab (version 17), a statistical software widely used around the world to analyze data.
- • Experience handling a few projects/case study by collecting data to gather real experience in using some statistical tools.
- • Learn a variety of statistical tools and understand how to use them at the different phases of a Lean Six Sigma project.
- • Able to differentiate between Lean and Six Sigma and show why Lean and Six Sigma methodologies are dependent on one another and a proven strategic system for managing the whole supply chain of a business.
- • Learn the importance of Change Management in relations to Six Sigma Quality Management.
- • Exposed to the idea of how Six Sigma can be implemented within an organization.
- • To identify process owners, internal and external customers, and other stakeholders in a project.
Who should take the course?
-
- • Managers
- • Project Leaders
- • Senior Engineers
- • Green Belt Candidates and anyone who desires an understanding of Lean Six Sigma principles and skills.
- • No previous Six Sigma and Lean experience is required.
Do I need to conduct a project to be certified?
No. However, in the absence of conducting a project, participants will be the assigned hands-on case study. This case studies will enable the participants to collect data and apply the statistical tools to gain an experience similar to conducting a project. Although these case studies cannot substitute the knowledge gained by doing an actual project, the simulation experienced through these case studies will play a role close enough to conducting an actual project. The following Case Studies will be assigned:
- Preparation of a Project Charter Case Study
- Developing a Micro Process Map Case Study
- Measurement System Analysis Case Study.