Lean Six Sigma Black Belt

Aims

Structure

16 days (day on Lean Six Sigma Awareness Workshop optional)

20 days (with Design For Six Sigma included)

There are 5 modules for Black Belt – 4 days, 3 days, 3 days, 3 days

There are 6 modules for Black Belt including DFSS – as above plus DFSS 4 day module

Content

The course includes a practical introduction and training on the full range of Lean Six Sigma tools.  On completion of this course delegates will be able to work as leaders of Lean Six Sigma DMAIC projects.  This course has proved to be equally relevant to manufacturing and services/transactional environments.  No prior knowledge of experience is required.  Each participant receives a comprehensive delegate pack including Catalyst’s Lean Six Sigma Improvement Toolbook, Statistical Tool guides, Worksheets, Project examples and support materials for use in Minitab.

This programme includes training on the advanced (statistical) tools required to execute the full range of Lean Six Sigma DMAIC projects. 

Practical exercises are incorporated to provide relevant scenarios for delegates.  During these modules each delegate will be required to use statistical software.  We use MINITAB™ Statistical Software in our training.  No prior knowledge of Minitab is needed.  A full practical introduction is included at the start of the programme.  Delegates will need to bring a laptop computer.

Module 1 is an accelerated foundation course concentrating on the Lean Six Sigma methodology.  It begins with a 1 –day Lean Six Sigma Awareness Workshop (optional).  Delegates then explore the Lean Six Sigma Project Structure to include:

• Change management

• Project definition

• Charters

• Stakeholder analysis

• Process mapping

• Voice of the customer

• Critical-To-Quality (CTQ)

• Input/output measures

• Data collection; control chart, root cause analysis and basic non-statistical tools

A number of individual and team exercises are used to reinforce the concepts and encourage use of the tools.

 

Module 2 topics include:

• Introduction to MINITAB™ Statistical Software

• Normality (Central Limit Theorem, P-values, Transforming Data)

• Sampling (Random and Process Sampling, Determining Sample Sizes, Selecting Samples)

• Measurement System Analysis (Data Types, Guage R&R, Attribute Agreement Analysis)

• Introduction to Hypothesis Tests (Z- and t-tests)

Module 3 topics include:

• Hypothesis Tests (Analysis of Variance and Chi-Square Tests)

• Regression (Simple, Multiple, Binary Logistic)

• Control Charts (Continuous and Attribute Data Charts)

• Process Sigma (Short and Long-Term Sigma, Determining Process Shift, Improvement Strategies)

• Introduction to Designed Experiments (Full and Fractional Factorial Designs)

 

Module 4 covers more advanced statistical analysis tools.  This module will begin with a challenging Lean Six Sigma case study that will take the delegates from initial project charter development through a designed experiment. Subsequent advanced training in:

• Regression analysis (with indicator variables, curvilinear regression and logistic regression)

• Hypothesis testing (non-parametric)

• Control charts (non-shewhart) and Design of Experiments (Taguchi) complete this module

Module 5 covers the ‘softer’ leadership tools required to lead Lean Six Sigma projects. Topics included in this 3 day module:

• Change Management

• Team Building

• Facilitation/conflict resolution

This module will be delivered through a combination of presentation, case studies, videos and hands-on exercises.

Module 6 - Innovation and Design for Six Sigma (DFSS) Option. 



This 4-day module will build on your knowledge of DMAIC and give you an excellent perspective on the DFSS methodology and how it may be applied.  Equally applicable to manufacturing to manufacturing and service environments, the tarining uses the House of Quality approach as its foundation.  This module provides training on the range of DFSS tools and techniques and shows clearly how these build on the DMAIC Lean Six Sigma Improvement tools.  Topics include:

• DFSS Introduction & Overview

• The challenges of Innovation

• An overview of DMADV (the Design for Six Sigma Framework)

• Overview of Quality Function Deployment & House of Quality DMADV building on DMAIC

• Linking DMADV with new product state gate processes

• Define

• Project start up

• Market and customer segmentation

• Change Management Challenges

• Measure

• Voice of the Customer and Introduction to advanced techniques

• House of Quality 1

• Benchmarking and setting design goals

• Design scorecards

• Analyse

• Functional Analysis

• House of Quality 2

• Creative Thinking

• Concept selection

• Design

• Building the design elements

• Lean design tools

• Simulation & Scale up (including design for operation)

• Capability Evaluation

• Robust Designs & Tolerancing

• Intro to DOE

• Verify

• Piloting & testing

• Control Planning

• Handover to operations

• How to prepare for a successful DFSS deployment

Associated Courses

• Lean Management Green Belt

• Lean Management Black Belt

Suitable for

This course will suit anyone who needs a thorough understanding of what Lean Six Sigma is and how it works in practice. 

Cost

Black Belt £4,920 per delegate

(Ex VAT)

Black Belt plus DFSS £5,995

(Ex VAT)