Six Sigma Green Belt Certification
A-B Tech and Eaton Electrical Group
Six Sigma Green Belt Certification Course
February 13, 2006
Asheville-Buncombe Technical Community College
Course Overview
This course is designed to certify participants as competent in the fundamentals of
the Six Sigma Green Belt Body of Knowledge.
1.
Certification requires:
a.
Completion of at least 80 percent of the in-class course work.
b.
Completion of the ten online Six Sigma modules and successful
completion of the ten online module post-assessments.
c.
Successful completion of all of the Competency Assessments (in-class
exams).
d.
Completion of a Green Belt Project (optional)
(Note: This requirement only applies to those participants whose
sponsoring company requires a project and where the Quality Manager/Black Belt
will validate the successful completion of the project).
2.
Course Length/Date/Time/Location:
a.
On-campus sessions: 70-hour, 2 week course. First week is February 1317, 2006 and second week is March 27-31, 2006. Each session meets from 8:30 to 4:30
pm (one hour lunch) at Harvey L. Haynes Center, Enka Campus, Room 128.
b.
On-line sessions: 15-hour, 10 modules. Course participants will
complete this portion of the course at their own pace by accessing content on the web.
3.
Cost: $1,450. Includes all in-class materials (except Minitab and laptops) and
access to the on-line web-based training modules.
Course Objectives
1.
Equip Green Belt Candidates with the tools required to support Six Sigma process
improvement projects in their companies.
2.
Ensure a minimum level of technical competence in the key six sigma disciplines
by requiring Green Belt Candidates to pass a series of Competency Assessments.
Student Outcomes and Samples of Behavior
Students will be knowledgeable in the five stages of the DMAIC model, will be
able to work within a team environment, and will be competent to use the fundamental
tools in each stage of the Six Sigma process. The following outcomes are directly linked
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Six Sigma Green Belt Certification
A-B Tech and Eaton Electrical Group
to the key course exercises and competency assessments (i.e. exams). Each participant,
upon completion of this course, will be able to:
1.
Breakdown a process into its component steps and organize them into a basic
process flowchart.
2.
Determine the measurement requirements for a simple project and setup a data
collection process.
3.
Perform and interpret a Gage R&R Study (both variables and attributes)
4.
Calculate DPMO and Six Sigma for a process output.
5.
Conduct a simple Capability Study
6.
Setup, conduct and interpret a scatter diagram for paired data.
7.
Develop, conduct and interpret a stratification analysis using ANOVA
8.
Conduct and interpret a one-sample t-test.
9.
Conduct and interpret a two-sample proportion test.
10.
Calculate the Correlation Coefficient for paired data.
11.
Build a simple process improvement plan based on results of analysis.
12.
Setup, construct and interpret simple control charts (X-Bar and R charts).
Course Materials
1.
Three-ring binder (slide copies and exercise materials)
2.
Primary textbook: The Six Sigma Way Team Fieldbook, by Pande, Neumann,
and Cavanagh.
3.
Reference textbook: Lean Six Sigma Pocket Toolbook, by the George Group
4.
On-line, web-based training modules.
Course Developer and Instructor: Douglas Jones. Credentials
Master of Science in Systems Management, University of Southern California.
SigmaPro certified Six Sigma Master Black Belt.
ASQ Certified Six Sigma Black Belt (CSSBB), Certified Quality Engineer (CQE), Certified
Quality Manager (CQMgr), Certified Quality Auditor (CQA).
QSA/Registrar Accreditation Board (RAB) Certified Quality Management System Auditor
(QMS-A) for ISO 9001:2000.
Note: On-line materials were developed by The Quality Group.
Requirements/Prerequisites: Laptop with Minitab Version 14
Participants are encouraged to have a laptop with Minitab 14. For those without a
laptop, the Productivity Institute has laptops (with Minitab) for student use while in the
classroom. It is highly recommended that all participants be familiar with how to use the
Minitab Statistical Software. For Green Belt candidates not familiar with Minitab, they
may gain this familiarity by attending the “Introduction to Minitab” course. Minitab
Version 14 (30-day trial version) is available for students to use on their own
laptops/desktops if they don’t yet have Minitab at the start of the course.
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Six Sigma Green Belt Certification
A-B Tech and Eaton Electrical Group
Recommended but not required:
1.
2.
Minitab “Basic Statistics” course.
Minitab “Statistical Quality Analysis” course.
To register:
Call/email Doug Jones at 828-254-1921 Ext 5822, djones@abtech.edu. Or go to
https://sr.coned.abtech.edu/welcome.htm for on-line registration and enter course ID
SEF-7000-011 in the course registration sheet. Seating is limited.
Course Content and Structure:
1.
In-class training (lectures, workbook and exercises) will follow the structure of
The Six Sigma Way Team Fieldbook. Hands-on exercises will be used throughout and
analytical work will utilize a combination of manual computational methods and Minitab
Statistical Software.
2.
Three extended cases studies/micro-labs are used as the primary method for
organizing/structuring classroom exercises and summarizing key learning outcomes.
These are:
a.
Damper Scrap Case Study. This is a completed Black Belt project
summarized in a 40-page report that is included in the student binder. It is used as a tool
to summarize “key learning outcomes” at the end of each stage of the DMAIC process.
b.
PageGrabber Corporation Product Return Project. The project is an
in-class six sigma project used in exploring the DEFINE-MEASURE-ANALYSIS stages
of the DMAIC process. Students are presented with the problem of a “sharp spike in
product returns by a key customer”. Using the skills developed in the class, they work in
small teams to clearly define the problem; set up and conduct a measurement plan; and
conduct a preliminary analysis of the data. Exercises in the course agenda are tied
directly to this project.
c.
Statapult Project. This project uses the classic Statapult machine (i.e. a
catapult used in statistical studies) to model a process that is producing an output that
does not meet customer requirements. Students work on this project through all stages of
the DMAIC process. Exercises in the course agenda are tied directly to this project.
3.
On-line web-based instructional modules. These 10 modules will take
participants approximately 15 hours to complete at their own pace. These modules will
provide information that will help participants better understand the six sigma principles,
concepts and statistics. The intent is to reinforce and clarify the material being covered
during weekly in-class lectures and exercises.
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Six Sigma Green Belt Certification
A-B Tech and Eaton Electrical Group
4.
Focus is on technical skills required by a Green Belt. Some formal team training
will be included in the course material; however, most of the team skills will be
embedded in and assessed as part of the technical exercises. Rationale: Limited time
requires the concentration of course hours on developing technical capability; and, most
companies have adequate internal assets to provide excellent team training.
5.
There will not be an outside class-directed project. Participants are
expected/encouraged to work on company projects as directed by their own black
belts/quality managers. Rationale: Individual projects are NEVER in sync with what is
being taught in class (they are either ahead or behind the classroom material), so external
projects will not be an integrated part of the curriculum. However, company quality
managers/black belts may require their participants to complete a Green Belt Project
before receiving certification.
6.
Exams will be used to assess competency. Exams (different versions) can be
taken up to three times to demonstrate competency in each technical area (i.e. this is not
a one-chance-or-you-fail system). Demonstrated competence in the Green Belt body of
knowledge is required for certification.
Green Belt Course Agenda (in-class sessions)
1.
Module 1: Introduction
A.
The Six Sigma Way
1)
2)
3)
B.
Three Ways to Six Sigma
1)
2)
3)
`
2.
Six Sigma: What is it?
System Alignment: Tracking the Xs and Ys
Six Ingredients of Six Sigma
Process Improvement: Finding Target Solutions
Process Design/Redesign
Process Management for Six Sigma Leadership
C.
Organizing for Six Sigma: The Seven Roles
D.
The Team Leader’s Toolkit
1)
2)
3)
4)
5)
Team dynamics and evolution
Team Facilitation
Basic Discussion Skills
Data Collection: Using the Right Tools
Organizational Communication
Module 2: Define Stage
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Six Sigma Green Belt Certification
A.
Selecting Projects (Ch. 4)
1)
2)
3)
4)
B.
2)
Guidelines for the Requirement Statement
Six Steps to Defining Customer Requirements (Worksheet)
Analyzing and Prioritizing: The Kano Analysis and Instructions
Getting Measures for Priority Requirements
Quality Function Deployment (QFD)
Do’s and Don’ts
Exercise: Brainstorm List of Customer Requirements
Identifying and Documenting the Process
1)
2)
E.
The Charter
a.
The Elements
b.
The Problem/Opportunity Worksheet
(Exercise: Generate Problem/Opportunity Statement)
(Project Charter Exercise)
c.
DMAIC Project Plan Worksheet
d.
Gantt Chart
e.
Stakeholder Analysis
Do’s and Don’ts
Defining the Customer Requirements
1)
2)
3)
4)
5)
6)
7)
D.
KISS
Three Selection Essentials
The Selection Process: The Seven Steps
a.
Review All Sources of Information About Your Business
b.
Identify Potential Projects: Pain, Goal, Rationale
c.
Screen Possibilities
d.
Operationalize Remaining Criteria
(Criteria Generation Exercise)
e.
Evaluate Projects Against Criteria and Select
(Multi-vote Exercise)
f.
Evaluation Set of Projects
g.
Draft Charter for Each Project
Do’s and Don’ts
The Team Project Charter and Work Plan
1)
C.
A-B Tech and Eaton Electrical Group
Type of diagramming: Top Level or Detailed?
SIPOC Analysis, Map and Suspect Areas
(Flowcharting Exercise - SIPOC)
Wrapping up Define Stage
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Six Sigma Green Belt Certification
1)
2)
3)
4)
F.
The Define Stage Checklist
Update Storyboard
Tollgate Review and Preparation Worksheet
Review and Update
The Form Stage of Team Development in Define Stage
1)
2)
3.
A-B Tech and Eaton Electrical Group
The Basics
Troubleshooting and Problem Prevention
Module 3: Measure Stage: Measuring Process Performance
A.
Basic Measurement Concepts
B.
Two Components of Measure
1)
Plan and Measure Performance Against Requirements
a.
b.
c.
d.
e.
(Exercise: Project Planning Worksheet: Measurement)
(A1) Select What to Measure (3 approaches)
(Exercise: Begin Measurement Planning Worksheet)
(Critical to Quality CTQ Exercise)
(Measurement Assessment Tree Exercise)
(A2) Develop Operational Definitions
(Exercise: Complete Operational Definition Worksheet)
(A3) Identify Data Sources
(A4) Prepare for Data Collection
(Sample Size Calculation Exercise)
(Exercise: Preparing a Data Collection Form)
(A5) Implement and Refine Measurement Process
(Gage R&R Study – Exercises for Continuous and
Discrete Data Sets)
2)
Develop Baseline Defect Measures and Identify Improvement
Opportunities.
a.
b.
(B1) Calculate Baseline Sigma Levels
(DPMO and Six Sigma Calculation Exercise)
(B1) Long-term versus Short-Term Variation and the Z-
value calculation.
(Exercise: Z-Table Calculations and Conversion to
Sigma-Level)
c.
d.
(B2) Calculate Final and First-Pass Yield
(Exercise: Calculate Final Process Yield)
(B3) Measure “Cost of Poor Quality”
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Six Sigma Green Belt Certification
C.
Wrapping Up Measure and Preparing for Analyze Stage
1)
2)
3)
4)
Refine Problem Statement
Create the Analyze Plan
Update Storyboard
Tollgate Review
D.
Team Guidance for the Measure Stage
E.
Competency Assessment. Perform a:
1.
2.
3.
4.
4.
A-B Tech and Eaton Electrical Group
Sample Size Calculation
DPMO and Sigma-Level Calculation
Z-Table Calculation and Interpretation
Gage R&R (Continuous Data: Minitab)
Module 4: Analysis Stage – Data Analysis
A.
Data Analysis: Exploring
1)
2)
3)
4)
5)
B.
Data Analysis: Hypothesis Generation
1)
2)
C.
D.
Three Principles:
Logical Cause Analysis
The Pareto Analysis
(Pareto Exercise)
Run/Trend Chart Analysis
(Run Chart Exercise)
Histograms
(Histogram: Capability Study Exercise)
Cause and Effect Analysis
(Cause and Effect Exercise)
Relations Diagramming
Data Analysis: Verifying Causes (3 Methods)
1)
2)
Causal Logic
Statistical Verification
(Scatter Diagram Exercise)
3)
Experimentation to Confirm Cause
Competency Assessment. Perform:
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Six Sigma Green Belt Certification
1)
2)
5.
Module 5:
A.
Detailed Sub-Process Mapping
Deployment Flowcharting
First-Level: The Obvious Problem Identification
Second-Level: The Value/Non-Value Adding Steps
Time Analysis
(Value-Stream Mapping Exercise – Optional)
C.
Process Analysis: Verifying Causes
D.
Team Guidance for the Analysis Stage
Module 6:
A.
Advanced Analytical Tools
C.
Hypothesis Testing
(Simple t-test Exercise for Continuous Data)
(ANOVA Exercise on Stratification Factors)
(Simple Proportion Test for Attribute Data)
Correlation/Linear Regression Analysis
(Exercise: Calculate Correlation Coefficient)
Experiments
D.
Competency Assessment. Setup, Conduct, and Interpret:
B.
1)
2)
3)
4)
7.
Analysis Stage – Process Analysis
Process Analysis: Generating Cause Hypotheses
1)
2)
3)
6.
Capability Study
Correlation Study Using Simple Scatter Diagram
Process Analysis: Exploring
1)
2)
B.
A-B Tech and Eaton Electrical Group
t-Test on One Continuous Data Set
A Correlation Study with the Coefficient
Stratification Analysis – Graphical and ANOVA
Two-Sample Proportion Test
Module 7: Improvement Stage
A.
Generating Creative Solutions Ideas.
B.
Synthesizing Solutions
(Tree Diagramming Exercise)
C.
Analyzing and Selecting a Solution
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Six Sigma Green Belt Certification
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A-B Tech and Eaton Electrical Group
D.
Pilot Testing
E.
Implementing Full-Scale Improvements
F.
Some Advanced Improvement Tools
(Failure Mode and Effects Analysis Exercise -- Optional)
G.
Preparing for the Control Stage
H.
Guidance for Teams in the Improve Stage
Module 8: Control Stage
A.
Discipline and Documentation of the Improvement
B.
Establishing Ongoing Process Measures
(Control Charting Exercise)
C.
Building a Process Management Plan
D.
Team Guidance for the Control Stage
E.
Ending a Project
F.
Competency Assessment -- Using Minitab:
Setup, Input Data and Interpret a Control Chart
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