LEAN SIX SIGMA BLACK BELT (LSSB-QA-04)
By completing the Lean Six Sigma Black Belt Certification course, students will be able to: Participate in the development of a successful Lean Six Sigma program. Contribute to the definition of project selection criteria and develop project proposals to meet those criteria. Lead a Lean Six Sigma project team, using the DMAIC problem solving methodology and team building skills. Apply and interpret basic and advanced Lean Six Sigma tools, as necessary, for project definition, process baseline analysis, process improvement, and process control. Demonstrate sufficient expertise of the Black Belt Body of Knowledge on an appropriate certification exam.
1. Introduction to Lean Six Sigma
-Definition of Lean Six Sigma & its relation to Cost and Efficiency.
-Popularity and Application of Lean Six Sigma.
-Comparisons between TQM and Lean Six Sigma Programs.
2. How to Deploy Lean Six Sigma
-Data driven decision making.
-Organizational metrics and dashboards.
3. Lean Six Sigma Projects
-Estimating Project Benefits.
-Overview of DMAIC methodology.
4. DEFINE Stage Tools & Objectives
-Define Stage Objectives.
-Project Charter: Use and Development.
5. DEFINE: Metrics & Deliverables
-Critical to Quality (CTQ) Metrics.
-Critical to Schedule (CTS) Metrics.
-Relation of CTQ and CTS Metrics to Critical to Cost (CTC) Metrics.
6. DEFINE: Project Financials
-Cost of Poor Quality.
-Quantifying Project Benefits.
7. DEFINE: Project Scheduling
-Scheduling Project Activities & Events.
-Critical Path Analysis / Activity Network Diagram.
8. DEFINE: Change Management and Lean Six Sigma Teams
-Problems with Change.
-Team Formation, Rules & Responsibilities.
9. Measure Stage Tools and Objectives
-Measure Stage Objectives.
-Process Definition (Flowcharts, Process Maps, SIPOC).
-Establishing Process Baseline.
10. MEASURE: Probability & Distributions
-General Probability Rules.
-Distribution Use & Interpretation in MS Excel and Minitab.
11. MEASURE: X-Bar Charts
-Construction & Calculations.
12. MEASURE: Individuals Data
-Uses, comparison with X-Bar chart.
-Construction, calculations, assumptions, sampling considerations and interpretation.
13. MEASURE: Process Capability
-Histograms Use and Misuse.
-Goodness of Fit Tests.
-Capability & Performance Indices.
14. MEASURE: Attribute Charts
-Selection (P, U, Np, C Charts).
-Construction & Calculations.
15. MEASURE: Short Run SPC
16. MEASURE: Measurement Systems Analysis
17. Analyze Stage Tools & Objectives
-Analyze Stage Objectives.
-Definition of Waste.
-Analyzing Process for NVA.
-Lead Time and Velocity.
-Methods to Increase Velocity.
-When are Batches More Efficient?.
18. ANALYZE: Sources of Variation
-Confidence Intervals on Means & Percents.
-Hypothesis Testing Method, Assumptions and Uses.
-Hypothesis Tests on Mean, Two Sample Means, Paired Samples.
-Hypothesis Tests on Variance, Two Sample Variances.
-Power & Sample Size Considerations.
19. ANALYZE: ANOVA
-Assumptions & Bartlett’s Equality of Variance Test.
-One-way ANOVA in Excel & Minitab.
-Two-way ANOVA in Excel & Minitab.
-Multi-factor ANOVA in Excel & Minitab.
-Tukey’s HSD Test.
20. ANALYZE: Regression Analysis
-Cause & Effect Diagrams.
-Correlation, Stratification, Extrapolation.
-Linear Regression Model.
-Interpreting the ANOVA Table.
-Confidence & Prediction Limits.
21. ANALYZE: Serial Correlation
-Batch Control Charts.
22. ANALYZE: Multiple Regression
-Interpreting ANOVA Tables.
23. ANALYZE: DOE Introduction
-DOE vs. Traditional Experiments.
-DOE vs. Historical Data.
24. ANALYZE: DOE Analysis Fundamentals
-Estimating Effects and Coefficients.
-Estimating Error & Lack of Fit.
-Extending Designs and Power of Design.
25. ANALYZE: Design Selection
-Performance: Balance, Orthogonality, Resolution.
-Other Design Models.
26. ANALYZE: Transformations
-Need for Transformations.
-Taguchi Signal to Noise Ratios.
27. Improve Stage Tools and Objectives
-Improve Stage Objectives.
-Tools to Prioritize Improvement Opportunities.
-Defining New Process Flow.
-Lean Tools to reduce NVA and Achieve Flow.
-Tools to Define & Mitigate Failure Modes.
28. IMPROVE: Response Surface Analysis
29. IMPROVE: Ridge Analysis
30. IMPROVE: Simulations
-Applying Probabilistic Estimates.
31. IMPROVE: Evolutionary Operation
-Risks & Advantages.
32. Control Stage Tools & Objectives
-Control Stage Objectives.
-Methods of Control.
33. Final Exam
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