Get Started With Six Sigma
Black Belt Certification

Basics of Six Sigma

Understand what is Six Sigma, Value of Six Sigma, Why Use Six Sigma over Other Methodologies, How Six Sigma Philosophy and Goals Should Be Applied, History of Six Sigma. Define Quality, Overview of Quality Approaches, Six Sigma Thinking, Six Sigma Transformation Approach. What it Means With Six Sigma, Six Sigma Metrics, Six Sigma Revolution – Current Users & More, Basic Statistics and Calculations, Measures of Centring, Sample Mean for a Distribution, Sample Median, Measures of Spread, Standard Deviation

Basics of Lean

Understand what is Lean, History of Lean. Understand what Muda is, Types of Muda (8 wastes) (Transport, Inventory, Motion, Waiting, Over Processing, Over Production, Defects, Skill Mismatch). Understand the concept and uses of 5S, Kaizen, Poka Yoke, Understand the concept of Takt time, its calculations and Lead time and its calculation, Lean Six Sigma – Differences, Benefits

Green Belt Day 1 – Pre Define Phase – 08 Hrs

Brief about Six Sigma, Six Sigma Levels, Roles & Responsibilities during projects, Who is a Customer, Types of Customers, Critical to Quality Roadblocks of Six Sigma, Understanding of project, Characteristics of a Good Project, Tools to Identify Projects, Six Sigma Levels, Roles & Responsibilities during projects

Green Belt Day 2 – Define Phase – 08 Hrs

Project Documentation, Defining the project (Project Charter – Business Case, Problem Statement/Opportunity Statement, Goal Statement, Project Scope and Boundaries, Project Benefits, Project Team, Project Timelines/Schedule), CAP Tools (ARMI & RASIC, Communication Plan, Stakeholder Analysis, Threats & Opportunity), Process Mapping (SIPOC / COPIS, Flow Chart shape & usage, Summary of Define Phase & Tollgate Review)

Green Belt Day 3 & 4 – Measure Phase – 12 Hrs

Describe & Establish Performance Standards, Measurement System Analysis (MSA), MSA Terminology, MSA Steps, Fixing equipment variation, Source of Variation, Identify Possible Causes, Prioritization of Possible Causes, Sampling, Sampling Technique, Sample Size, Sampling Calculation & Sampling Types, Data Collection Plan (What, How and Who will collect), Data Type, Data Source, Data Range, Time Period, Baseline Process Objectives (Normality, Stability & Capability).

Green Belt Day 4 & 5 – Analyse Phase – 12 Hrs

Process Analysis using Value Stream Mapping, Value Stream Analysis, Types of Non-Value-Added Works, Workflow & Time Allocation, Activity Workflow – Track the Unit Flow, 7 QC Tools, Logical Order of 7 QC Tools, Hypothesis testing, The Nature of Statistical Problem, Why do Hypothesis Testing, Nature of H0 & Ha, Criminal Trial Analogy, Decision Error & Types, Types of Hypothesis Tests

Green Belt Day 6 – Improve & Control – 8 Hrs

IMPROVE

Set Improve Objectives, Improve Phase Actions, Characterization of X’s, PICK Chart, Prioritization Matrix, Control Impact Map of the vital X – Project, Solution Identification & Prioritization, Idea Generation, Solution Design Selection, Understand FMEA & Its Objectives, Severity of FMEA, Occurrence of FMEA, Detection of FMEA, when is FMEA Useful, Preparing FMEA, Identifying Cause, Rating and RPN, The Pilot – Proof of Concept, Running a Pilot

CONTROL

Statistical Process Control (SPC) / Statistical Quality Control (SQC),Variation, (Common Cause Variation, Special Cause Variation) , Control Charts, Types of Control Charts, Control Limits v/s Specification Limits, Process State. Understand Variable Control Charts, Assumptions for Variable Charts, IMR Charts, X-Bar R Chart, Discrete Control Charts – C Chart, U Chart, NP Chart, P Chart, Process Control System, Risk Management, Develop Control Plan, Develop Control Plan, Who Owns IT?, Control – Summary, Cost Benefit Analysis, Documentation & Project Handover, Cost Benefit Analysis (CBA), Document the details, Handover Project

Lean Manager Day 1 – 8 Hrs.

Understand Lean 6 sigma, Origin of Lean, Roles & Responsibilities, Focus area of Lean, Benefits of Lean 6 sigma, Gemba Walk, Lean Thinking Principals, Value of Lean 6 sigma, Muda, Mura, Muri, Waste Counter Measures, Value Stream Mapping & Symbols used in VSM.

Lean Manager Day 2 – 8 Hrs.

A3, Toyota Production System, JIT, Heijunka, Jidoka, Total Productive Maintenance, Standard Works, 5S & Visual Management including resistance to 5S & Red Tags, Visual Control (Andon Board), Theory of constraints, Kano Model, 5 whys, Kaizen Setup/change over reduction, Mistake proofing, Spaghetti Chart, Action workout, Pugh Metrics, Change Management Culture & Leadership, Stakeholder Summary of Lean Tools

Black Belt Day 1 & 2 – Predefine – 10 Hrs

Understanding of Quality, Types of Approaches to Measure Quality, Introduction to Various Approaches & Terminology (ISO, CMMI, COPC, Lean, Six Sigma, BPR, PDCA, PDSA, Balance Scorecard & KPI), Six Sigma History, Statistical Definition & Definition, Difference in Green Belt, Black Belt & Master Black Belt, Understanding of Project, Who is Customer, What is CTQ, What is VOC, Characteristic of Good Project, Idea to Commence Project, COPQ Analysis, Tools to Identify Projects (Kano, Brainstorming), VOC Prioritization Tools ( QFD ), Describe Project Financial Benefits Using ROI, ROA , Payback Cycle, NPV , CBA, Formation of Project Team Selection, Roadblocks of Six Sigma Implementation and Solution, Describe 7 Management & Planning Tools

Black Belt Day 2 & 3 – Define – 08 Hrs

Describe & Explain Project Snapshot & Documentation For Project, Understand & Design Project Charter Component, Business Case, Problem Statement, Goal Statement, Scope & Boundaries, Qualitative & Quantitative Benefits, Milestone For Each Phase Using Gantt Chart, CAP Tools, Role & Responsibility Alignment Using ARMI & RASIC, Stakeholder Analysis, Threats Vs Opportunity, Describe Process Map Using SIPOC, COPIS, Flow Chart, Work Instruction, Written Procedure, Tollgate Review, Preparation, Potential Failure, Communication Approach, Sign-off

Black Belt Day 3 & 4 – Measure – 14 Hrs

Describe how to establish Performance Standard (Operational Definition, Unit, Opportunity, Defect, Defective, Specification Limit), Introduction of Statistical Software Package (Minitab) & Various Functions. Measurement System Analysis (MSA), Analyse MSA for Discrete Data (Attribute Agreement Analysis), Analyse MSA for Continuous data (Gage R&R, Gage ANOVA), Explain Process of Plan, Do, Conduct & Analyse MSA, Identify Possible Causes Using Brainstorming, Represent Idea by Fishbone & Prioritize Using Control Impact Matrix, Design Data collection plan for various X & Y for Hypothesis Testing and Baseline Data, Understand Possible Failure & Impact, Describe Data Distribution Type, (Binomial Distribution, Poisson Distribution, Normal Student/ T Distribution, Z Distribution, Chi-square Distribution), Manual Calculation With Example Of Confidence Interval, Standard Error, Probability Density Function of Above Distributions), Understanding of Sample Size Calculation With Example, Describe Baseline Concept, Understand the Characteristic of Normality, Various Tools to Check Normality, For X & Y, Single & Multiple Population, Normality & Concept of Anderson Darling Normality Test, Describe Skewness & Kurtosis With Example And Target Value, Explain Importance of Stability, Special & Common Cause Variation, Tools to Measure Stability (I-mr Chart, Run Chart), Types of Run Chart, (Mixture, Cluster, Trend, Oscillation, Describe About Process Capability for Various Data Shape (Normal, Non-normal), Understand Capability indices (Cp, Cpk, Pp, Ppk, Cpm) Data Transformation Using Box Cox Power Transformation, Johnson Transformation etc. Understand Capability Measure Using Minitab or Manual

Black Belt Day 5 & 6 – Analyse – 16 Hrs

Describe Process Analysis Using Value Stream Mapping (Value Add, Non-Value Add, Business Value Add, Cycle Time & Lead Time) Process Cycle Efficiency, VSM Example, 7 QC Tools with Example Practical in Minitab

(Flow Chart, Check-Sheet, Histogram, Pareto, Scatter Plot, Control Chart & Fishbone), Describe Box Plot in Minitab, Understand Calculation of Outliers, Explain Various Terminology Used in Box Plot and Examples, Describe What Is Hypothesis Testing, Hypothesis Concept, Criminal Trail Analogy, Producer & Consumer Risk, Type of Hypothesis, Null Hypothesis Ho & Alternate Hypothesis Ha, P Value Concept & Acceptance Criteria, Define, Select & Interpret The Result Of Hypothesis Testing For Continuous Project & Continuous Factor (YcXc), Define, Select & Interpret the Result of Hypothesis Testing For Continuous Project & Discrete Factor, YcXd, Describe Hypothesis Testing for Continuous Project & Discrete Factor, YcXd, Centering Related Test Parametric Test, Describe Hypothesis Testing for Continuous Project & Discrete Factor, YcXd, Centering Related Test-Nonparametric Test, Accumulate Result of Analyse Phase, Stakeholder Discussion & Agreement, Explain Summary Table Format, Describe and Define About Experiments, Experiment Objectives, Experimental Methods, Experiment, Introduction of Design of Experiment, Explain Factor, Level, Run, Effect, Response, Noise Factor, Experimental Run, Calculation of Required Experiments, Replication, Repeated Measure (Repetition), Confounding, Order (Run Order and Standard Order), Randomization, Blocking, Main Effects, Interaction Effects & Resolution (III, IV, V), Full Factorial Design and Fractional Factorial Design

Black Belt Day 7 – Improve – 8 Hrs

Describe and Explain Solution Generation Technique (Brainstorming, Anti-Solution, Card Method, Multi-Voting, Quality Function Deployment, Understand & Implementation of Lean Tools, Theory of Constraint (TOC), Heijunka, Jidhoka, 5S {SEIRI (Sort) SEITON (Set in Order) SEISO (Shine) SEIKETSU (Standardize) SHITSUKE (Sustain)}, Poka-Yoke, We Will Cover in Lean Management Training), Explain Prioritization of Solution Using Cost Benefit Analysis (CBA) or PICK Chart (Potential, Implement, Consider, and Kill), PUGH Matrix, Heat MAP, Describe and Explain Risk Assessment Using FMEA (PFMEA, DFMEA), Possible Risk Before Pilot Implementation, Prioritization Using RPN, Risk Management System, Risk Treatment Plan, Pilot Implementation, Concept of Pilot, Scale & Scope, Validation of Improvement Using Various Hypothesis Test (Paired T Test, Mann Whitney Test, 2 Variance Test / 2 Standard Deviation Test, 2 Proportion Test), Box Plot & Histogram, Explain Full Scale Implantation, Validation of Improvement Against Project Goal Statement Using (1 Sample T Test, 1 Sample Z Test, 1 Sample Sign Test, 1 Sample Wilcoxon 1 Proportion Test), Measurement System Analysis for Improved Process.

Black Belt Day 8 – Control – 8 Hrs

Understand and Explain on How to Validate Process Performance Sustainability Using Statistical Process Control, Statistical Quality Control, Common Cause Variation, Special Cause Variation, Types of Special Cause Variation, Control Charts for Continuous (I-MR, X-R, X-S), Control Chart for Discrete (C, U, NP & P) Charts, Describe and Explain Risk Assessment Using FMEA (PFMEA, DFMEA), Possible Risk Before Pilot Implementation, Prioritization Using RPN, Risk Management System & Risk Treatment Plan, Design Control Plan for Performance Stability Which Include Defining Activity, Frequency of Activity, Responsible Person & Escalation Matrix and Communication Plan, Apply Lean Tools to Sustain Performance (Poke-Yoke) & 5 S Perform, Cost Benefit Analysis (CBA) For Overall Project Investment, Overall Return for Short Term and Long Term, Project Documentation, Train Employees in New Process, Communicate Using A3 Tools, Handover to Department Manager, Celebration –Project Benefit Celebration for Project Team And Respective Department to Encourage Continuous Improvement Culture