Lean Six Sigma Black Belt - India

Lean Six Sigma Black Belt Course Outline

Module 1: Introduction to Lean 6 Sigma

• What is Lean 6 Sigma?
• Lean 6 Sigma Belts
• Processes
• Customers, Value, and Waste
• Key Metrics

Module 2: Reviewing Process and Qualities

• What is DMAIC?
• Define
• Measure
• Analyze
• Improve
• Control

Module 3: Yellow Belt Tools and Techniques

• Lean Triad
• Voice of the Customer (and CTQ’s)
• SIPOC
• Value Stream Analysis
• Heijunka
• Variation and SPC
• Defects and Process Capability
• Identifying the Root Cause(s)
• Solving Problems
• Introduction to Kaizen
• Lean Teams

Module 4: Improvement Methodologies

• DMAIC
• 3Cs
• 8Ds
• Plan Do Check Act
• Kaizen
• Design for Six Sigma (DFSS)

Module 5: SPC Basics

• Terminology
• Data Types
• Normal Distribution and Standard Deviation
• Process Capability

Module 6: Lean Management and Cell Theory

• Role of the Lean Manager
• Work Cells
• High Performing Teams (HPTs)
• Rapid Action Teams (RATs)
• Visual Management
• Bruce Tuckman’s Group Development Model
• Emotional Cycle of Change (ECOC)
• Personality Styles
• Dealing with Resistance

Module 7: Risk Management

• Green Belt Risk Management
• FMEA: Failure Mode and Effects Analysis

Module 8: DMAIC for Green Belts

• Define Phase
• Measure Phase

Module 9: SPC Tools and Techniques

• Frequency Distribution Tables
• Bar Charts and Histograms
• Pareto Charts
• Box and Whisker Plots
• Normal Distribution and Control Charts
• Calculating Process Efficiency
• Scatter Diagrams and Regression

Module 10: Analyze Phase

• Analyze
• Process Maps
• Process Map Levels
• On the Ground Instructions (OTGIs)
• Value Stream Maps
• What is a Value Stream?
• Creating the “As Is” VSM
• Investigating and Understanding the Process
• Headache Tablets: Value Stream Mapping
• Creating a VSM: Process Borders Definition
• Using Swim Lane Diagrams to Identify Logical Process Blocks
• Process Boxes
• VSM Metrics
• Square Wave
• Kaizen Burst
• Creating an Improved Process
• Layout Diagrams and Headache Tablets

Module 11: Improve Phase

• Heijunka
• Solutions Identified, Selected, Planned, and Implemented
• Standardization and Documentation
• Communications and Training

Module 12: Control Phase

• Embed the change
• Measure the gain
• Close the project

Module 13: Role of the Black Belt

• Black Belts’ Place in the Business
• Black Belt Skill Set
• Green Belts’ View of the World
• Black Belts’ View of the World
• How Industry Identifies Black Belts?
• Who does the Black Belt Work with?
• Case Study

Module 14: Black Belt DMAIC

• How the Black Belt helps the Green Belt During DMAIC?
• Measure Phase
• DMAIC Programs
• Governance

Module 15: Enterprise Risk Management

• Risks Lie in Two Areas
• Who Should Handle Risk?
• DMAIC Risk
• A view of Business Risk Management
• Basic Risk Management Procedure
• Business Risk Management in a Nutshell

Module 16: Physical Cell Design and Optimizing Flow

• In a Nutshell
• Task & Work Cells
• Flow Improvement Objectives
• Practical Layout Design

Module 17: Black Belt as a Trainer

• Characteristics of Adult Learners
• Three Common Learning Styles
• Preparing the Training
• Top Tips
• Case Study

Module 18: Statistics Basics

• Introduction and SPC Refresh
• Common Terminology
• Flow Improvement Objectives
• Measuring Uncertainty
• Minitab Run-through

Module 19: Process Capability

• Process Capability: Review from Green Belt

Module 20: Hypotheses Tests

• Introduction to Hypotheses Testing
• Working with Hypotheses Tests
• Hypothesis Test Roadmap
• Anderson Darling Normality Test
• To Open the Worksheet
• The Results
• Testing for Means
• t-tests Consider More than Just the Means…
• t-test Exercise
• Z test
• Testing for Medians
• Where Could I Use Median Tests?
• Median Hypothesis Tests
• Testing for Standard Deviation (Variance)
• Equal Variance Hypothesis Tests
• Exercise: Test for Equal Variance
• Interpreting the Results
• Using Bartlett’s Method
• Testing for Proportions and Percentages
• Proportions and Percentages Hypothesis Tests

Module 21: Exercise Using Minitab’s – 2 Proportion Test

• Scenario
• Abbreviated Instructions
• Reviewing the Results

Module 22: Exercise Using Minitab’s - Chi-Square Test

• Scenario
• Abbreviated Instructions
• Interpreting the Results

Module 23: ANOVA

• Required conditions for ANOVA
• The ANOVA “family”
• ANOVA Terminology
• Hypotheses Tests and One-way ANOVAs
• Exercise - One-way ANOVA
• Exercise - Multi-way ANOVAs

Module 24: Data Collection Planning for Hypotheses Tests

• General Points
• Sample Size
• How a Greater Sample Size Reduces Uncertainty?
• Case Study

Module 25: Design of Experiments (DOE)

• Overview of DOE
• Where to Use Design of Experiments?
• DOE Terminology (1)
• Design of Experiments Flow Diagram
• Walkthrough: SB Glass Co
• Step 1: Investigate the Process
• Step 2: Gather Data
• Recording the Data: Building the Worksheet
• Minitab Creates an Initial DOE Worksheet
• Team Completes the Worksheet
• Step 3: Analyze Data
• Teams’ First Analysis of the Data
• Minitab does its Stuff

Module 26: Probability Distributions

• Overview
• Normal Distribution
• Binomial Distribution
• Poisson
• Exponential
• Weibull

Module 27: Advanced Control Charts

• Introduction and Refresher
• Key Control Charts
• Data Collection Planning for Control Charts

Module 28: Measurement System Analysis (MSA)

• General overview
• Key Metrics
• Using Lean Metrics

Module 29: Lessons from Queue Theory

• Overview
• Understanding Gauge R&R
• Minitab Walkthrough

Module 30: Lean Metrics

• Modelling Queues
• Psychology of Queuing