Six Sigma Black Belt Training

Section 1:
Module 1: Introduction and organization wide considerations  

• Fundamentals of Six Sigma
  • What is Six Sigma and its success stories
  • History of Six Sigma
  • Six Sigma DMAIC methodology
  • Process Mapping / process thinking
  • Role of Black Belt
  • Relationship – Six sigma and Lean
  • Organization wide considerations
    • Six Sigma, Lean and Continuous improvement
      • When to use six sigma
      • Problem solving approaches
      • Integration and complementary relationships
    • Strategic planning and deployment for initiatives
      • X-Matrix, Portfolio analysis, SWOT, PEST
    • Relationship among business systems and processes
      • Internal and external stakeholders
      • Impact of relationships on business processes

Section 2:

Module 2: leadership and Six Sigma

• Leadership roles and responsibilities
  • Describe roles and responsibilities of leadership
  • Champions, sponsors, process owners, master black belts and green belts in driving six sigma and lean initiatives
  • Impact of each group on managing resources a organizational structure and supporting communication
• Organizational roadblock and change management
  • Impact of culture and structure on Six Sigma
  • Causes of six sigma failures
  • Applying change management techniques
  • Organizational process management and measures
• Impact on stakeholders
• Benchmarking
• Performance and financial measures
• Team Management
  • Team types and constraints
  • Team roles and responsibilities
  • Team member selection criteria
  • Team facilitation techniques
    • Motivational, stages of development, team communication, team leadership models
    • Team dynamics: Group Behaviours, meeting management, team decision making methods
    • Team training: Needs assessment, Delivery and Evaluation

Section 3:  

Module 3: Define

• Voice of the customer
  • Customer identification
  • Customer data collection
  • Customer requirements
  • Business case and Project Charter
    • Business case and problem solving
    • Project scope, goals and objectives
    • Project performance measurements
    • Project charter view
  • Project Management tools
    • Gantt charts
    • Toll gate reviews
    • Work Breakdown Structure
    • RACI Model
  • Analytical Tools
    • Affinity diagrams
    • Tree diagrams
    • Matrix diagrams
    • Prioritization matrices
    • Activity network diagrams

Section 4:

Module 4: Measure

• Process characteristics
  • Process flow metrics
  • Process analysis tools
• Data Collection
  • Types of data
  • Measurement scales
  • Sampling
  • Data collection plan and methods
• Measurement systems
  • Measurement system analysis
  • Measurement system across the organization
  • Metrology
• Basic Statistics
  • Basic statistical terms
  • Central limit theorem
  • Descriptive statistics
  • Graphical methods
  • Valid statistical conclusion

Section 5:

Module 5: Measure (Continued)

• Probability
  • Basic concepts
  • Distributions
• Process capability
  • Process capability indices
  • Process performance indices
  • General process capability studies
  • Process capability for attributes data
  • Process capability for non-normal data
  • Process performance vs. Specification
  • Short term and long term capability

Module 6: Analyze

• Measuring and modelling relationship between variables
  • Correlation coefficient
  • Linear regression
  • Multivariate tools
• Hypothesis testing
  • Terminology
  • Statistical Vs. Practical significance
  • Sample size
  • Point and interval estimates
  • Test for means, variance and proportions
  • Analysis for variance (ANOVA)
  • Goodness of Fit (chi-Square)tests
  • Contingency tables
  • Non parametric tests

Section 6

Module 7: Failure Mode and Effect Analysis (FMEA)

Module 8: Additional Analysis Methods

• Gap analysis
• Root cause analysis
• Waste analysis

Module 9: Improve

• Designs of Experiments (DOE)
  • Terminology
  • Design principles
  • Planning experiments
  • One-factor experiments
  • Two level fractional factorial experiment
  • Full factorial experiment
• Lean methods
  • Waste elimination
  • Cycle-time reduction
  • Kaizen
  • Other improvement tools and techniques
  • Implementation

Section 7:

Module 10: Control

• Statistical Process Control (SPC)
  • Objectives
  • Selection of variables
  • Rationale sub grouping
  • Control chart selection
  • Control chart analysis
• Other controls
  • Total productive maintenance (TPM)
  • Visual controls
• Maintain controls
  • Measurement system re-analysis
  • Control plan
• Sustain improvements
  • Lesson learned
  • Documentation
  • Training for process owners and staff
  • On-going evaluation

Module 11: Design for Six Sigma (DFSS) Framework and Methodologies

• Common DFSS methodologies
• Design for X (DFX)
• Robust Design

Training Summary
Discussion and Guidance
Training evaluation
Certificate distribution