Lean Six Sigma Black Belt

Lean Six Sigma Black Belt – overview

Our Black Belt programme gives participants a thorough exposure to all the tools and methods necessary to successfully lead Lean DMAIC improvement projects in an operational environment. The emphasis is on hands-on exercises and tutorials to ensure rapid learning and knowledge retention.

This 8-day programme is delivered in two modules of four days each (typically with a month between modules) to allow participants to apply what they have learned to a project within their own business while under the guidance of one of our highly experienced Master Black Belts.

The project should be challenging yet of a scale that can be progressed as far as possible during the training.

Full details below or download course outline.

Learning objectives

By the end of the programme participants will have completed, or gone substantially towards completing, a project from their own organisation. The training will encompass:

  • The history of Lean and Six Sigma
  • The DMAIC process improvement roadmap
  • How to establish customer requirements
  • How to measure and quantify process performance
  • Lean tools and their application
  • Statistical and analytical methods for identifying and understanding sources of variation
  • Experimental design techniques leading to mathematical models of products and processes
  • Optimisation techniques to maximise process performance with minimum variation
  • Innovative thinking techniques
  • Team and change management techniques to ensure effective projects
  • Sustainment and control techniques

See also the detailed ‘learner outcomes’ for each module, below.

Who should attend?

Those who have completed the Green Belt programme and intend to move into a coaching and mentoring role as well as taking on multi-function projects.

Course format

The course includes extensive practical analysis exercises and all participants will need access in the classroom to a laptop / computer with Minitab installed.

This eight-day training programme is delivered in two modules of four days each (typically with a month between modules) to allow participants to apply what they have learned to a project within their own business while under the guidance of one of our highly experienced Master Black Belts. A certificate of attendance is awarded upon successful completion of the programme.

Given the practical nature of this workshop-style programme, there is a maximum limit of twelve participants (minimum four).

Special features

It is strongly recommended that participants come to the start of the programme with either a well-defined project or a number of project ideas. The project can then be used as a learning and application vehicle. During the training there will be opportunities between the modules for the participants to be mentored and coached by the Master Black Belt.

This programme is very practical and is based on all participants having a laptop or PC in the training room with Minitab installed. Minitab is the leading statistical software package used for quality improvement worldwide. If the course participants do not already have experience of using Minitab then they should attend an Introduction to Minitab first.

Lean Six Sigma Black Belt – programme outline

MODULE ONE

Learner outcomes

Participants will be able to:

  • Extend the use of VOC capture and the first House of Quality to detailed product or process design, and process control using a succession of QFD matrices
  • Decide how to deal with non-normal data
  • Use appropriate control charts for attribute data
  • Assess process capability where process performance measures use attribute data
  • Identify appropriate hypothesis tests to use, depending on types of data and decisions to be made
  • Use CUSUM (cumulative sum control chart) analysis to test for historical changes in level in process data
  • Use appropriate regression analysis techniques to identify potential X/Y relationships where there are multiple Xs and various types of data
  • Design and analyse the results of a screening experiment
  • Design and analyse the results of a response surface study and generate a model of the process
  • Use optimal design or augmentation techniques to create a response surface study when existing experimental evidence is available and valid to use
  • Optimise the X settings and tolerances using a previously generated process model and specialist software
  • Use EVOP (evolutionary operations) techniques to apply experimentation and optimisation techniques to running processes without adverse effects



Module outline

DAY ONE

1 Introductions / expectations / agenda

  • Review Green Belt training and experience
  • Black Belt agenda

2 Requirements flowdown

  • Introduction to concept
  • Use of a series of matrices
  • Link to DFSS (design for Six Sigma)

3 Dealing with non-normal data

  • Distribution identification and characterisation
  • Transformation
  • Practical, graphical, analytical
  • Distribution shape
  • Reasons for non-normality

4 Control charts re-visited

  • Introduce the appropriate charts for attribute data types

5 Process capability re-visited

  • Appropriate methods for attribute data types
  • Calculating equivalent metrics for different types of data
  • Exercises – Generating attribute data and analysing it using control charts and process capability; M and M’s game
  • Opportunity for participants to present on project progress and seek advice on next steps


DAY TWO

1 Review of Day One

2 Hypothesis testing re-visited

  • Principles
  • Further tests
  • Exercises

3 ANOVA

  • Principles involved
  • Calculations
    • – Random, fixed and mixed effects
    • – Residual analysis
  • ANOVA for more than one X
    • – Analytical options available in Minitab
    • – Link to DOE (design of experiments)
    • – Balanced and unbalanced designs

4 CUSUM methodology

  • Introduction to cumulative sum control charts
  • Detecting shifts in data
  • Exercise – CUSUSM workshop
  • Opportunity for participants to present on project progress and seek advice on next steps


DAY THREE

1 Review of Day Two

2 Regression toolkit

  • Introducing regression with multiple Xs
  • Techniques for using various types of data
  • Exercise – regression using Minitab

3 Designed experiments

  • Introducing the concept
  • Screening experiments approach
  • Creating process models using RSM (response surface methods)
  • Noise factors
  • Exercise – coating thickness

4 Designing and running a Response Surface Experiment

  • Build a model of the process
  • Optimise the performance of it
  • Exercise – Gyrocopter
  • Present results
  • Opportunity for participants to present on project progress and seek advice on next steps


DAY FOUR

1 Review of Day Three

2 Alternative, efficient approaches to RSM design

  • Pre-existing and valid experimental results
  • Xs involved which have different numbers of levels
  • Optimal design and augmentation
  • Assessing the adequacy of the design
  • Exercise – path of steepest ascent

3 Robust tolerance analysis

Introducing the concept
Effective optimisation of input settings and tolerances
Achieving required output performance on processes
Exercise – RSM coating thickness

4 The EVOP approach

  • Evolutionary operation of processes
  • Conformance with requirements

5 Summary

  • Review
  • Expectations for Module Two
  • Q and A
  • Expectations for project activity and reporting for next module



MODULE TWO

Learner outcomes
Participants will be able to:

  • Consider the use of a variety of creativity tools when generating concepts for improved products or processes
  • Apply force field analysis to help them with the implementation of change in business processes
  • Apply the PEST and SWOT analysis tools to help them to understand constraints and opportunities when considering product or process change
  • Apply the principles of total productive maintenance within their company processes
  • Explain the principles behind the Taguchi loss function, and how it links to the Six Sigma approach
  • Use the Taguchi approach to robust design by planning, running, analysing and drawing conclusions from a Taguchi experiment
  • Use FMEA (failure modes and effects analysis) to evaluate the robustness of products and processes and make appropriate improvements
  • Recognise the fundamentals of team management, and their importance to delivering successful project outcomes
  • Apply the full DMAIC process and appropriate tools to an in-class case study



Module outline
DAY ONE

1 Introductions / expectations / agenda

  • Review Module One
  • Agenda for Module Two

2 The Improve phase – further tools and techniques for generating new concepts

  • 9-dot square and 4 lines puzzle
  • Creative innovation ppt
  • Solution tree.doc
  • Contradictions matrix
  • Exercise – Titanic workshop
  • Workshop feedback and discussion
  • Pugh concept selection matrix
  • Design convergence
  • Force field analysis
  • PEST and SWOT

3 Theory of constraints

  • Principles
  • The goal

4 DMAIC – Define and Measure phases

  • Exercise – statapult workshop



DAY TWO

1 Review of Day One

2 Total productive maintenance techniques

  • Equipment and maintenance methods used

3 Taguchi loss function

  • Acceptable v unacceptable losses
  • Marketplace perception of the quality

4 Robust design

  • The Taguchi approach
  • S/N ratios
  • Exercise – tile experiment

5 Define noise factors

  • Parameter design and tolerance design
  • Taguchi’s approach to experimental design
  • Additive characteristics
  • Special arrays, etc

4 DMAIC – Analyse phase

  • Exercise – statapult workshop
  • Opportunity for participants to present on project progress and seek advice on next steps



DAY THREE

1 Review of Day Two

2 Robust design (cont)

  • Interactions
  • Taguchi arrays

3 DOE (design of experiments)

  • Re-evaluate understanding
  • Working in Minitab

4 DMAIC – Improve phase

  • Using RSM, Taguchi, process settings
  • Exercise – statapult workshop
  • Prepare and present a Powerpoint presentation on the DMAIC workshop
  • Opportunity for participants to present on project progress and seek advice on next steps



DAY FOUR

1 Review of Day Three

2 Risk analysis and process improvement tool

  • FMEA
  • Process FMEA
  • Design FMEA
  • Exercise – FMEA workshop

3 The essentials of team management

  • Exercise – team management

4 DMAIC – Control phase

  • Exercise – statapult workshop

5 Final DMAIC workshop presentation

6 Conclusion

  • A review of the whole programme
  • Expectations and requirements for achieving Certified Black Belt status, including passing an exam and presenting projects
  • Where next?


Participants will continue to progress their projects after the end of the programme. E-mail support will still be available from the Master Black Belt.