Lean Six Sigma Black Belt Certification Training

Introduction to Define Phase

Learning Objectives

Six Sigma

Lean

Sigma Shift

Yield

Continuous Improvement Process Evolution

Six Sigma Deliverables

Problem Solving Strategy

VOC Campaign

VOC Tools

VOB

VOE

KANO Analysis

Six Sigma Roles and Responsibilities

Project Champion and Master Black Belt

Black Belt and Yellow Belt

Drivers of Six Sigma

Key Takeaways

Learning Objectives

Process

Project Charter

Critical to Quality (CTQ)

Cost of Poor Quality (COPQ)

Calculating COPQ

Pareto Analysis (80-20 rule)

Basic Six Sigma Metrics

Key Takeaways

Learning Objectives

Lean

Principles of Lean

Lean Methodology

Lean and Six Sigma

3Ms of Lean

Categories of Waste TIMWOODS

Category of Waste DOWNTIME

5S

Steps in 5S: Part One

Steps in 5S: Part Two

Key Takeaways

Activity

Solution

• Course Introduction

Introduction to Measure Phase

Learning Objectives

Tools to Define a Process

Cause-and-Effect Diagram

Drawing a Fishbone Diagram

Root Cause

Process Mapping

Creating a Process Map

Process Mapping Levels

Four Types of Process Maps

Value Stream Maps

Value Stream Maps: Key Metrics

X-Y Diagrams or Scatter Plots

Failure Mode and Effects Analysis FMEA

FMEA Process

FMEA Template

Severity Occurrence and Detection Table

Risk Priority Number (RPN)

Key Takeaways

Learning Objectives

Data

Measurement Scales

Basic Statistics

Measures of Central Tendency

Measures of Dispersion

Data Collection Plan

Data Collection Plan: Steps

Develop a Measurement Plan

Collect Data

Sampling

Sampling Methods

Graphical Analysis

Graphical Analysis: Tools

Demo: Introduction to Minitab

Demo: Box Plot One Variable

Demo: Box Plot with Three Variables

Demo: Time Series Plot

Normal Distribution

Standard Normal Distribution

Demo: Normality Test

Key Takeaways

Learning Objectives

Measurement System Analysis: Overview

Good and Poor Measurement System Analysis

Measurement Error Categories

MSA Sources of Variation

Repeatability

Reproducibility

Accuracy

Bias

Stability

Linearity

MSA Types

Gage R&R Guidance in MINITAB

Gage R&R Ground Rules

Demo: Gage R&R Continuous Data

Attribute Agreement Analysis (AAA)

Attribute Gage Study

Demo: Gage R&R Attribute Data

Key Takeaways

Learning Objectives

Process Capability Overview

RUMBA Analysis

Process Capabilities

Data Types

Baseline Performance: Part One

Baseline Performance: Part Two

Components of Variation

Process Stability

Process Capability Indices

Demo: Capability Analysis Continuous Data

Process Capability Indices: Example

Demo: Capability Analysis Continuous Data Sigma Level

Z Score

Process Baseline

Defects per Unit

Defects per Million Opportunities

Attribute Data: Example

Short-Term and Long-Term Process Capability

Key Takeaways

Activity

Solution

Introduction to Analyze Phase

Learning Objectives

Frequency Distribution

Demo: Histogram

Probability Distribution

Types of Probability Distributions

Types of Discrete Probability Distributions

Types of Continuous Probability Distribution

Key Takeaways

Learning Objectives

Inferential Statistics

Branches of Inferential Statistics

Central Limit Theorem (CLT)

Key Takeaways

Learning Objectives

Basics of Hypothesis Testing

Confidence Interval

Significant Difference Between Datasets

Detecting Significance

Statistical Hypothesis Test

Hypothesis Testing Risks

Beta Risk

Power of a Hypothesis Test

Sample Size

Hypothesis Testing Roadmap

Key Takeaways

Learning Objectives

Normal Data

One-Sample T-test

One-Sample T-Test: Sample Size

Demo: One-Sample T-Test

Two-Sample T-Test

Two-Sample T-Test Example

Demo: Two-Sample T-Test

Demo: Bartlett Test

Paired T-Test

Demo: Paired T-Test

Z-Test For Hypothesis Testing

ANOVA

Demo: ANOVA

Residual Plots

Key Takeaways

Learning Objectives

Non Parametric Tests

Mann Whitney Test

Demo: Mann Whitney Test

Kruskal Wallis Test

Demo: Kruskal Wallis Test

Mood's Median Test

Demo: Mood's Median Test

Friedman Test

Demo: Friedman Test

One-Sample Sign Test

Demo: One-Sample Sign Test

One-Sample Wilcoxon Test

Demo: One-Sample Wilcoxon Test

One-Sample Proportion Tests

Demo: One-Sample Proportion Test

Two-Sample Proportion Tests

Demo: Two-Sample Proportion Test

Chi-Square Tests

Demo: Chi-Square Test of Independence

Chi-Square Goodness-of-Fit Test

Demo: Chi-Square Goodness of Fit

Chi-Square Cross Tabulation

Demo: Chi-Square Cross Tabulation

Demo: Two-Sample T-Test with Levene F-Test

Key Takeaways

Exercise One

Exercise Two

Introduction to Improve Phase

Learning Objectives

Correlation

Demo: Correlation

Demo: Correlation Test Using Scatter Plot

Correlation and Causation

Predictor Measures and Results

Correlation Coefficients

Regression Analysis

Demo: Regression

Residual Analysis

Key Takeaways

Learning Objectives

Multi-Vari Analysis

Demo: Multi-Vari Analysis

Nonlinear Regression

Multiple Linear Regression

Demo: Multiple Linear Regression

Variance Inflation Factor VIF

Variance Inflation Factor VIF: Example

Confidence Interval for Multiple Linear Regression

Box-Cox Transformation

Demo: Box-Cox Transformation

Key Takeaways

Learning Objectives

Design of Experiments (DOE)

Phases of DOE Process

Optimization and Confirmation Phase

Types of DOE Strategies

Full Factorial and Fractional Factorial Approaches

Principles of Experimental Design

Key Takeaways

Learning Objectives

Factorial Designs

Full Factorial Experiments

Demo: Full Factorial Experiments

Quadratic Models

Types of Response Surface Designs

Balanced and Orthogonal Designs

Center Points

Fractional Factorial Experiment

Confounding

Key Takeaways

Learning Objectives

Competitor Analysis

Benchmarking, Types of Benchmarking, and Best Practices

Team Tools

Pugh Analysis and Solution Prioritization Matrix

Process Redesign and Optimization

Cost Benefit Analysis CBA

Pilot Testing, Implementation, PDCA, and Prototyping

Project Plan

Project Plan Schedule

Project Plan Risks

Quality Fucntion Deployment QFD

Failure Modes and Effects Analysis FMEA

Change Management in Lean Six Sigma

Roadmap for Design for Six Sigma

Key Takeaways

Introduction to Control Phase

Learning Objectives

Control Methods of Five S

Sort

Set in Order

Shine, Standardize, and Sustain

Kanban

Kanban Principles

Six Steps to Implement Kanban

Poka-Yoke or Mistake Proofing

Mistake Proofing: Examples

Key Takeaways

Learning Objectives

Statistical Process Control: Purpose

Control Charts

Control Charts: Objectives

Control Charts: Uses

Control Charts: Types

Control Charts: Steps

Subgroup

Considerations for Rational Subgrouping

Charts for Attribute Data

Tests for Special Causes

Demo: I-MR Chart

Demo: X-Bar-R Chart

Demo: XBar-S Chart

Demo: P-Chart

Demo: NP-Chart

Demo: U-Chart

Demo: C-Chart

Demo: CUSUM-Chart

Demo: EWMA-Chart

Key Takeaways

Learning Objectives

Project Cost Benefit Analysis

Return on Investment (ROI) and Return on Assets (ROA)

Cost Benefit Analysis

Cost Benefit Analysis: Steps

Net Present Value (NPV) and Internal Rate of Return (IRR)

Selecting the Right Solutions

Implementation of Proposed Solutions Roadmap

Elements of a Control Plan

Training, Monitoring, and Aligning Systems and Structures

Response Plan

Project Closure

Key Takeaways

Excercise