Black Belt Training

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