LeanSixSigmaBlackBelt
ThecoreroleoftheBlackBeltistoleadsignificantLSSprojectsandtheirremitoften
includescoachingGreenBeltsandsupportingProjectChampions.Thistrainingprogramme
hasbeenconfiguredtoprovidetheexpertisetoachievetheseobjectivesbutadditionally
willequipdelegatestobecomeprocessexpertsandinternalconsultants.
Themodulesare:
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GreenBelt(4daysopen/6daysin-house)
ProcessMeasurementandControl(3days)
DataAnalysisTechniques(3days)
ManagingChange(3days)
AdvancedBlackBeltTools(3days)
Optional,buthighlyrecommended:
• LeanSixSigmaforInnovationandDesign(3days)
Themodulescanbetakeninrapidsuccessioninonetrainingwaveorspreadoutovera
longertimeperiod.Ifyouhavealreadycompletedsomeofthemodules,youcanupgrade
toBlackBeltfromyourcurrentposition.
LeanSixSigmaGreenBelt
Introduction:
• KeyprinciplesandfoundationsofLeanandSixSigma
• WasteandFlow
• VariationandSigmavalues
• RolesandResponsibilities
• Thesystematicapproach(DMAIC)
• ProjectSelection
• IntrotoChangeManagement
TheprogrammethenfollowstheDMAIC(Define,Measure,Analyse,Improve,Control)
phases,wecover8stepswithinthisframework,coveringrelevanttoolsandtechniques
undereachoftheseheadingsasfollows:
DefinePhase:
Step1-SelecttheProblem
• ImprovementCharter
• SIPOC
• FocusontheCustomer
• Voiceofthecustomerandbusiness
• CriticalToQualityrequirements
• Inframe/outofframe
• Stakeholderanalysis
• Elevatorspeech
MeasurePhase:
Step2–UnderstandtheCurrentSituation
• ProcessStapling
• Valueaddedflowanalysis
• Processmapping:DeploymentFlowChartsandValueStreamMapping
• MomentsofTruth
• Datacollection
• VOCtoCTQMatrix
• CTQtoOutputMeasuresmatrix
• OperationalDefinitions
• MeasurementPlans
• ContinuousandAttributedata
• IntroductiontoGaugeRandR
• Datacollectionmethods
• YtoX(outputtoinputs)matrix
• Output,InputandIn-processmeasures
• IntroductiontoSamplingmethods
• Variation
• StatisticalProcessControlCharts
• Special&CommonCauseVariation
• ProcessCapability
• ProcessSigma
AnalysePhase:
Step3-Identify&CheckthePossibleCauses
• Fishbone/Ishikawadiagrams
• NegativeBrainstorming
• InterrelationshipDiagrams
• Developingmeasurementsofpossiblecauses
• ProcessFlowandWaste
• IntroductiontoDataAnalysisTechniques
• ParetoCharts
• BasicGraphs
• Scatterdiagrams
• HypothesisTests
• RegressionAnalysis
• IntroductiontoDesignofExperiments
• LogicalCausetesting
• Financial&Tollgatereviews
• IntroductiontoMulti-GenerationalPlans
ImprovePhase:
Step4–GeneratePossibleSolutions
• LeanSolutions
• SMED
• Batchsizereduction
• Pullprocessing
• ProductFamilies,3RsandCells
• IntroductiontoTheoryofConstraints
• ProcessLevellingandSequencing
• 5S
• Creativethinking
• AssumptionBusting
• Catalyst
• IdeasBox
Step5–SelecttheSolution
• N/3andPairedComparisons
• PrioritisationMatrices
• ForceFieldAnalysis
• XYgrids
Step6–Plan&TesttheSolution
• ProcessPilot
• FMEA
• PokeYoke
• FinancialReview-Costbenefitanalysis
ControlPhase:
Step7–Implement&StandardisetheSolution
• Processmanagement
• VisualManagement
• ControlPlans
• Standardisation
• Documentation
• ResponsePlan
• ControlCharts
Step8–AssessAchievements&Lessons
• Storyboards
• FinalReview/PostProjectReview
• Recognition
ProcessMeasurementandControl
Day1:
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Day2:
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ProcessSamplingwithcontinuousanddiscrete(attributeandcount)data
SampleSizecalculationsforcontinuousanddiscretedata
MeasurementSystemsAnalysis
o GaugeR&RStudy
o AttributeAgreementAnalysis
RecapofUnderstandingVariationandSPC,TestsforSpecialCauses
Individuals(X-movingRange)SPCCharts
ControlChartsinPractice
Day3:
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IntroductiontoBasicStatisticsandGraphicalAnalysisusingMinitab
ThissessionintroducesMinitabandbuildsupyourknowledgeofthesoftware(no
previousexperiencerequired)usingacasestudy.Toolsinclude-
o FrequencyPlots
o ScatterPlots
o ParetoCharts
o TimeSeriesPlots
StatisticalThinking
o TheNormalDistribution
o NormalityTesting
o DataTransformationandwhentouseit
o Introductiontop-values
o CentralLimitTheorem
SixSigmaMeasuresandProcessCapability
o DPU/DPMOanddeterminingnumberofopportunities
o SigmaCalculations
o CapabilityIndices(Cp/CpK,Z)
o SixSigmaShift
DataAnalysisTechniques
Day1:
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HypothesisTesting
o Ttestsforcomparing2groups
o TypeIandTypeIIErrors
o PowerandSampleSize
o ANOVAandTestforEqualVariancesforcomparingmultiplegroups
o ProportionsandChiSquaretestsfor2ormoregroups–discretedata
Day2:
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RegressionAnalysis
o LinearRegression
o MultipleLinearRegressionandModelBuilding
o Curvilinearregression
o IntroductiontoLogisticRegression
Day3:
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ControlCharts
o ChartsforAttributeData(p,np,c,u,Laney)
o Chartsforsub-groupeddata(Xbar-R,Xbar-S,X-MR-R/S)
IntroductiontoDesignofExperiments–FactorialExperiments
CaseStudy
ManagingChange
Day1
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ImportanceofManagingChangeinLeanSixSigmaProjects
ChangeProcessOverview
DevelopingthecompetenciesofasuccessfulChangeAgent-effectivefacilitation
Impactofculture,historyandresistanceonchange
Day2
• DevelopingthecompetenciesofasuccessfulChangeAgent-visioning,management
ofselfandothers,persuasionandinfluencingskills
• TheroleofStakeholdersinchange
• ManagingtheStatesofChange–current,transitionandfuture
Day3
• DevelopingthecompetenciesofasuccessfulChangeAgent–buildingandmanaging
effectiveprojectteams,managingconflict
• PlanningforChange-communications,traininganddevelopment,reward&
recognition
• Changeprogrammeandprogressmonitoring
AdvancedBlackBeltTools
Day1:
AdvancedANOVA
• GeneralLinearModel-ANOVAwith2ormorefactors
• MainEffectsandInteractions,co-variates
Furthert-testtopics
• Transformingdataforrobustness
• 1sidedtestsand1sampletests
Non-ParametricHypothesisTests
AdvancedRegression
• RegressionmodelwithcontinuousanddiscreteXs
• Transformingdatatoimprovethemodel
• Usingthemodel
Introductiontostepwiseandbestsubsetsregression
Day2:
LogisticRegression
• SingleandMultipleBinaryLogisticRegression
• OrdinalLogisticRegression
DesignofExperiments
• FullFactorialandFractionalFactorialExperiments
• PlanningandDesigningtheexperiment-blocking,randomisingandreplication,
practicalconsiderations
• AnalysingtheExperiment–plots,residualsanalysis,reducingthemodel
• Usingthefinalmodel–responseoptimiser,predictions
Day3:
IntroductiontoProcessSimulationsoftware
Time-WeightedControlCharts
TimeSeriesandSeasonality
ThebroaderroleoftheBlackBelt
• LeanSixSigmadeployment,roles,projectmanagementandreview,financials,Black
Beltcompetencies
• RevisionCaseStudy–CoveringtheDMAICphasesfromDefinethroughtoControl
Optional:LeanSixSigmaforInnovationand
Design
Createthefutureforyourorganisation
AsaLeanSixSigmapractitioner,areyoufindingthatimprovingyourexistingproducts,
processesandservicesisnotsufficienttomeetyourgoals?
Areyoufrustratedwithunsuccessfulattemptstoinnovatebrandnewwaysofdoingthings?
Doyouwanttodesignnewproductsorservicesquicklyandrightfirsttime?Doyou
sometimeswishyoucouldstartwitha‘blanksheetofpaper’anddevelopanewconcept
thatexcitedthecustomer,was‘lean’,flexible,responsive,andwasdefectfreefromday1?
ThiscoursebuildsonyourexistingknowledgeofimprovementandDMAICmethodology
andprovidesanadditionalandcomplementaryrangeoftoolsandtechniquestosupport
highlyeffectiveandrapidinnovation.
Objectives
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Empoweryourselftobemoreeffectiveincreatingthefutureofyourorganisation
WhentoapplyDMADVversustheDMAICprocess?
UnderstandtheDMADVprocessandthetoolsyoucanapplytoyourprojects
Designandtollgatereviewsandhowthesereviewsshouldbeconductedand
managed
“Thebestwaytopredictthefutureistocreateit.”
PeterF.Drucker,AmericanManagementGuru
SoWhyandHowDoesLeanSixSigmaHelp?TheLeanSixSigmaInnovationandDesign
Journey
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Providesadesignmethodologythatintegratescustomerfocusandstructuredtools
withasystematicdesignprocess.
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Atotaldesignapproachthatmaintainsfocusonthecustomerthroughout
theprocess
ConsideruseofTollgatesandDesignReviewstoassureappropriategovernanceof
innovationdevelopmentwork
Describeandpracticeanextendedrangeoftechniquestocaptureandanalysevoice
ofcustomer
Build"HouseofQuality"matrices,usingQualityFunctionDeployment,throughan
extensiveanddetailedcasestudy
Day1
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IntroductionsandObjectives
ImportanceofInnovationandDMAICvsDMADV?
ChangeManagement
DEFINE:SegmentingCustomersandMulti-GenerationPlanning
MEASURE:VOCtechniquesandissues
Day2
QFD,creatingthe‘HouseofQuality’
CTQsandratingneeds,CompetitiveandBenchmarkassessment
ValuePropositionandDesignScorecards
ANALYSE:FunctionalAnalysis,TransferFunctionsandHOQ2
ConceptDevelopmentandTesting
Day3
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DesignElementsandHighLevelDesign
CapabilityEvaluation,ModellingandRisk
DESIGN:DetailedDesignandDesignofExperiments
DesignIntegrationandPilotplanning
VERIFY:PilotingandImplementation
Control,ProcessManagement,TransitionandClosing
Supportedbylotsofexercisesanddiscussionbreaks
CourseOutline
TheCurriculumisbuiltaroundacasestudyandavarietyofpracticalexercisestogive
participantsrealhandsonexperienceinapplicationofLean-SixSigmathinkingand
techniquestothechallengesfacedwheninnovationanddesignisrequiredinyour
organisation.
Introduction&Overview
Theimportanceofeffectiveandrapidinnovationtomodernbusinessandbarriersto
success,AnoverviewofDMADV(theLSSIDFramework)andwhyitmakesthecritical
difference,QualityFunctionDeploymentandthe‘HouseofQuality’,DMADVbuildingon
DMAIC,LinkingDMADVwithnewproductstagegateprocesses.
Define
Projectstartup,Marketandcustomersegmentation,thechangemanagementchallengesof
DMADV.
Measure
VoiceoftheCustomerandIntroductiontoadvancedVOCtechniques,QualityFunction
Deployment(HouseofQuality1),Benchmarkingandsettingdesigngoals,Design
scorecards,Definingthevalueproposition.
Analyse
FunctionandFunctionalAnalysis,HouseofQuality2,CreativeThinking,Concept
development,testingandselection,BuildingtheDesignElements,Simulation.
Design
DetailedDesignplanning,Leandesigntools,ModellingandIntroductiontoDesignof
Experiments,assessingDesignCapability,RobustDesigns,DesignIntegration,Design
Review,RiskManagement.
Verify
Pilotingandtesting,ControlPlanning,ImplementationandHandovertooperations/BAU