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NIQC International’s Certified Lean Six Sigma Black Belt (CLSSBB) Program is the third level of Lean Six Sigma Training Module. This training program focusses on making you best in class in quality management and continuous improvement
During the training you will be able to understand the concepts of DMAIC & DFSS methodologies and its implementation, understand methods to identify projects, understand and implement high end tools like Quality Function Deployment, Design Of Experiment hypothesis and their usages. Attain hands on experience of various tools like 7 QC tools and Hypothesis testing, understand and analyse Minitab software.
College Placement is considered to be one of the most important tools for the selection of colleges in India. It is a significant measure of success since the students’ ultimate goal is to leverage their college degree into a rewarding, lifelong career. Thus, our team decided to take up the “Improvement of Campus Placement Rate” as our project for Six Sigma.
The Business Case for our project: The college chosen for the project, deals with more than 5000 intakes every year. The placement department handles the placements for these students every year. But there has been a decline in the placement rate which affects the college reputation and thus affects the admission rate/ no. of intakes which causes both qualitative and quantitative loss for the institution.
The goal was to increase the placement rate to around 95% by the end of the next academic year (2020-21). At the end of the project, we saw a significant improvement in the campus placement, and most importantly, we were able to plan out a better placement process that can be continuously improved as well as sustained for the coming years.
Our main focus in the project was to use the voice/requirements of the organization as well as the customer i.e. students so that the process can be improved quickly.
Hence, after many brainstorming sessions as well as fishbone analysis, we were able to get the main areas under the whole process, which requires improvement. But the backing of data was needed as well. Hence, we collected data for the past 5 years, did the analysis on them using various analytical tools and software, and hence, derived key problems that had to be taken care of.
Thus, to assess this, we again went to the organization as well as the students to sort out which were the key problems as per their point of view. After all these processes, we prepared a control plan in which we tried to find out the solution to these problems which were acceptable to both students as well as the organization.
Now, the aim was to see whether the control plan can improve and sustain the process or not. Hence, after the next placement procedure, we did a cost-benefit analysis which proved that our project was successful and our goal was achieved.
Understanding of Quality, Types of Approaches to Measure Quality, Introduction to Various Approaches & Terminology (ISO, CMMI, COPC, Lean, Six Sigma, BPR, PDCA, PDSA, Balanced Scorecard & KPI).
Six Sigma History, Statistical definition & definition, difference in Green belt, Black Belt & Master Black belt
Understanding of Project, Customer, CTQ, 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
Describe Basic Statistics for Centring & Variation ( Mean , Median, Mode, Range, Quartile, Variance & Standard Deviation), Manual Calculation with Example
Describe & Explain Project Snapshot & Documentation for Project, Understand & design project charter component (Business Case, Problem Statement, Goal Statement, Scope & Boundaries, Qualitative & Quantitative Benefits, and milestone for each phase using Gantt Chart)
CAP tools (Role & responsibility alignment using ARMI & RASIC, Stakeholder Analysis and Threats Vs Opportunity)
Describe Process Map using SIPOC, COPIS, Flow Chart, Work instruction & Written Procedure
Tollgate Review, preparation, potential failure, Communication approach and sign-off
Describe how to establish Performance Standard (Operational Definition, Unit, Opportunity, Defect, Defective, Specification limit)
Introduction of Statistical Software Package (Minitab) and various functions, Measurement system Analysis (MSA), Learn how to analyse MSA for discrete data (Attribute Agreement Analysis) & 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, Poisson, 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), Mixture, Cluster, Trend and 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
Describe Process Analysis using Value Stream Mapping, Value Add, Non Value Add, Business Value add, Cycle Time & Lead Time, Process Cycle Efficiency, VSM example
Explain 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, 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( Yc Xc)– Correlation, Scatter Plot, Understand Regression Equation Y=Bo+B1 X Concept, R, R-squared Value with Example, Multi-Co-Linearity, Matrix Plot, Simple Linear Regression, Multiple Regression, Fitted Line Plot & Variance Inflation Factor
Define, Select & Interpret the Result of Hypothesis Testing for Continuous Project & Discrete Factor, Yc Xd, Variation Related Test, 1 Variance, 1 Standard Deviation, 2 Variance, 2 Standard Deviation, Test of Equal Variance, F Test, Bartlet Test & Levene Test, Example in Minitab.
Describe Hypothesis Testing for Continuous Project & Discrete Factor, Yc Xd, Centering Related Test- Parametric Test, 1 Sample T- Test, 1 Sample Z Test, 2 Sample T Test, Data Unstack Process, Paired T Test, 1 Way ANOVA
Describe Hypothesis Testing for Continuous Project & Discrete Factor, Yc Xd, Centering Related Test- Nonparametric Test, 1 Sample Sign Test, 1 Sample Wilcoxon Test, Mann Whitney Test, Moods Median Test, Kruskal-Wallis Test
Describe Hypothesis Testing for Discrete Project Yd & Continuous Factor Xc- Binary Logistic Regression Test, Ordinal Logistic Regression Test, Nominal Logistic Regression Test
Describe Hypothesis Testing for Discrete Project Yd & Discrete Factor Xd- 1 Proportion Test, 2 Proportion Test, Chi-square Test, One Variable (Goodness-of-fit) Test with Equal Proportion & Specific Proportion, Two-Way Table Test & Cross Tabulation
Accumulate Result of Analyze Phase, Stakeholder Discussion & Agreement, Explain Summary Table Format, Describe & 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, Confounding, Order, Randomization, Blocking, Main Effects, Interaction Effects & Resolution, Full Factorial Design and Fractional Factorial Design
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, (Covered 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 ( Hypothesis tests are already covered in Analyze phase)
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 & 1Proportion test ( Hypothesis tests are already covered in Analyze phase)
Measurement System Analysis for improved process. ( Already covered in 3.2)
Understand & 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 & Explain Risk Assessment using FMEA (PFMEA, DFMEA), Possible Risk Before Pilot Implementation, Prioritization using RPN, Risk Management System & Risk Treatment Plan (Covered in 3.2)
Design Control Plan for Performance Stability which Include Defining Activity, Frequency of Activity, Responsible Person & Escalation Matrix & Communication Plan
Apply Lean Tools to Sustain Performance (Poke- Yoke) & 5 S (Covered in Lean Management Training)
Perform Cost Benefit Analysis for Overall Project Including Investment & Overall Return for Short Term & Long Term, Project Documentation, Train employees in New Process, Communicate using A3 Tools, Handover to Dept Mgr, Project Benefit Celebration for Project Team & respective Dept to Encourage Continuous Improvement Culture
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