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See description of materials for these turn-key Lean Six Sigma Instructor Training materials.
The following 35 topics are included in the Lean Six Sigma Black Belt Instructor Materials, containing all the subject matter (and workshops) necessary for effective training of your Lean Six Sigma Yellow Belts, Champions, Green Belts and Black Belts:
Introduction to Six Sigma (27 slides)
Definition of Six Sigma & its relation to Costs and Efficiency.
Popularity and Application of Six Sigma
Comparisons between typical TQM and Six Sigma Programs.
How to Deploy Six Sigma (35 slides)
Leadership responsibilities
Resource allocation
Data driven decision making
Organizational metrics and dashboards
Six Sigma Projects (35 slides)
Project Focus
Is it a Six Sigma Project?
Customer Focused Projects
Selecting Projects
Estimating Project Benefits
Overview of DMAIC methodology
Project Reporting
Training & Personnel (43 slides)
Management Training
Champion Selection & Training
Black Belt Selection & Training
Green Belt Selection & Training
Ongoing Training
DEFINE Stage Tools & Objectives (31 slides)
Define Stage Objectives
Project Charter: Use and Development
Work Breakdown Structure.
Pareto Diagrams.
Process Maps.
SIPOC
Matrix Diagrams
DEFINE: Metrics & Deliverables (37 slides)
Critical to Quality (CTQ) Metrics
Throughput Yield (and comparison to traditional yield)
Rolled Throughput Yield
Normalized Yield
DPMO: Use and Misuse
Sigma Level
Critical to Schedule (CTS) Metrics
Cycle Time
Process Cycle Efficiency
Process Velocity
Overall Equipment Effectiveness (OEE)
Relation of CTQ and CTS Metrics to Critical to Cost (CTC) Metrics
DEFINE: Project Financials (27 slides)
Cost of Poor Quality
Quantifying Project Benefits
CTC Calculations.
DEFINE: Project Scheduling (21 slides)
Scheduling Project Activities & Events
Gantt Chart
Critical Path Analysis / Activity Network Diagram.
PERT Analysis
DEFINE: Change Management and Six Sigma Teams (39 slides)
Problems with Change
Achieving Buy-In
Team Formation, Rules & Responsibilities
Stages of Team Development
Overcoming Problems
Consensus Building
Affinity Diagram
Nominal Group Technique
Prioritization Matrix
Measure Stage Tools and Objectives (44 slides)
Measure Stage Objectives
Process Definition (Flowcharts, Process Maps, SIPOC)
Metric Definition
Establishing Process Baseline
Enumerative vs. Analytic Statistics.
Process Variation (Deming's Red Bead)
Benefits of Control Charts.
Requirements vs. Control (Tampering)
Control Chart as Process Baseline Tool
MEASURE: Probability & Distributions (32 slides)
General Probability Rules.
Distribution Use & Interpretation in MS Excel and Minitab
Binomial Distribution
Hypergeometric Distribution
Poisson Distribution
Normal Distribution
LogNormal Distribution
Exponential Distribution
Weibull Distribution
Probability Plots
Goodness of Fit Tests
Curve Fitting with Johnson Distributions
MEASURE: X-Bar Charts (35 slides)
Uses / Assumptions
Construction & Calculations.
Assumptions
Rational Subgroups
Sampling Considerations.
Interpretation (including Run Test Rules)
MEASURE: Individuals Data (32 slides)
Uses, comparison with X-Bar chart
Construction, calculations, assumptions, sampling considerations and interpretation:
Run Charts
Individual-X / Moving Range Charts
Moving Average Charts
EWMA Charts.
MEASURE: Process Capability (24 slides)
Histograms Use and Misuse
Probability Plots
Goodness of Fit Tests
Capability & Performance Indices (Relative to Process Control; Interpretation; Estimating Error)
MEASURE: Attribute Charts (27 slides)
Uses
Selection (P, U, Np, C Charts)
Construction & Calculations
Sampling Considerations
Interpretation
MEASURE: Short Run SPC (14 slides)
Uses
Calculations
Nominals chart
Stabilized Chart
MEASURE: Serial Correlation (25 slides)
Applications
Estimating Autocorrelation
Interpreting Autocorrelation
Batch Control Charts
MEASURE: Measurement Systems Analysis (38 slides)
Stability Studies
Linearity Analysis
R&R Analysis
Range Method Calculations
Interpretation
Using Control Charts
Destructive Tests
ANOVA Method
MEASURE: Green Belt Data Collection Workshop (9 slides)
Data Collection Activity
MSA Analysis of Data
Control Chart Analysis of Data
Capability Analysis of Data
Analyze Stage Tools & Objectives (32 slides)
Analyze Stage Objectives
Definition of Waste
Analyzing Process for NVA
Cycle Efficiencies
Lead Time and Velocity
Takt Time
Methods to Increase Velocity
Standardization
Optimization
Spaghetti Diagrams
Level Loading
When are Batches More Efficient?
Setup Reductions
ANALYZE: Sources of Variation (40 slides)
Multi-vari Plots
Confidence Intervals on Means & Percents
Hypothesis Testing Method, Assumptions and Uses
Hypothesis Tests on Mean, Two Sample Means, Paired Samples
Hypothesis Tests on Variance, Two Sample Variances
Contingency tables
Power & Sample Size Considerations
Non-parametric Tests
ANALYZE: ANOVA (23 slides)
Assumptions & Bartlett's Equality of Variance Test.
One-way ANOVA in Excel & Minitab
Two-way ANOVA in Excel & Minitab
Multi-factor ANOVA in Excel & Minitab
Tukey's HSD Test
ANALYZE: Regression Analysis (37 slides)
Cause & Effect Diagrams.
Scatter Diagrams.
Correlation, Stratification, Extrapolation
Linear Regression Model
Interpreting the ANOVA Table
Confidence & Prediction Limits.
Residuals Analysis.
Overview of Multiple Regression Tools including Designed Experiments
ANALYZE: Multiple Regression (33 slides)
Multivariate Models.
Interaction Plots.
Interpreting ANOVA Tables.
Model Considerations.
Step-wise Regression.
Residuals Analysis.
ANALYZE: Transformations (22 slides)
Need for Transformations
Non-Constant Variance
Box-Cox Transforms
Calculated Parameters
Taguchi Signal to Noise Ratios
ANALYZE: DOE Introduction (32 slides)
Terminology
DOE vs. Traditional Experiments
DOE vs. Historical Data
Design Planning
Selecting Responses
Selecting Factors and Levels
Complete Factorials
Fractional Factorials
Aliasing
Screening Designs
ANALYZE: DOE Analysis Fundamentals (31 slides)
Estimating Effects and Coefficients
Significance Plots
Estimating Error & Lack of Fit
Extending Designs
Power of Design
Tests for Surface Curvature
ANALYZE: Design Selection (30 slides)
Desirable Designs
Performance: Balance, Orthogonality, Resolution
Other Design Models
Saturated Designs
Plackett Burman Designs
Johns 3/4 Designs
Central Composite Designs
Box Behnken Designs
Taguchi Designs (mention)
Improve Stage Tools and Objectives (33 slides)
Improve Stage Objectives
Tools to Prioritize Improvement Opportunities
Defining New Process Flow
Lean Tools to reduce NVA and Achieve Flow
5S
Level Loading
Tools to Define & Mitigate Failure Modes
PDPC
FMECA
Preventing Failures
Reference to Tools for Defining New Process Levels
IMPROVE: Response Surface Analysis (22 slides)
Objectives
Applications
Sequential Technique
Steepest Ascent
IMPROVE: Ridge Analysis (26 slides)
Graphical Method
Analytical Method
Overlaid Contours
Desirability Function
IMPROVE: Evolutionary Operation (19 slides)
Methodology
Example
Risks & Advantages
IMPROVE: Simulations (21 slides)
Applications
Examples
Applying Probabilistic Estimates
Control Stage Tools & Objectives (19 slides)
Control Stage Objectives
Methods of Control
Control Plans
Training
Measuring Improvement
Design for Six Sigma Overview (32 slides)
Methodology
Tools for DFSS
System, Parameter and Tolerance Designs