Lean Six Sigma Black Belt

– Minitab®

Course Content and Outline

Course Estimated Hours: 139.10

Session 1: Introduction to Lean Six Sigma (4.65 Hours)

o Introduction o DNA of a Champion
o Higher Standards for Higher o Lean Six Sigma Framework
Performance o DMAIC - The Improvement Process
o Input Determines Output o Lean and DMAIC
o Lean Six Sigma Defined o Thought Process Mapping - Toolset
o What's In a Name? o Organizing for Success
o The 5 Lean Principles o Working Relationships
o The 8 Forms of Waste o Critical Success Factors
o Success Stories o Introduction to Minitab®
o The Sigma Level o Exercises and Quiz
o The 99.9% Problem

Session 2: Define I – Starting A Project and Leading Teams (8.80 Hours)

o Getting Started – Project Initiation o Developing an Effective Team
o Balanced Scorecard Toolset o Improving Team Development
o Project Selection Toolset o 4 Conversations Toolset
o Project Charter Toolset o Leading Change
o Project Planning & Tracking Toolset o Leading Change – Continued
o Leadership Thinking o Success Factors For Effective Change
o Robot Leadership Management
o Fueling The Improvement Engine o Leader Standard Work Toolset
o Leadership Characteristics o Stakeholder Analysis – RACI Matrix
o Practice, Study and Reflection - o Leadership Reflection
Learning by Modeling o Exercises and Quiz
o Leading Teams

Session 3: Define II – Voice of the Customer (8.05 Hours)

o Voice of The Customer o Understanding Customer
o Focus on The Customer Requirements

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Session 3: Define II – Voice of the Customer (Continued)
o Where to Go For Customer o Affinity Diagram Toolset
Requirements o CTQC Tree Diagram Toolset
o Conducting Surveys o Operational Definition Toolset
o Survey Considerations o Voice Of The Customer As
o Surveys – Sampling Frame Specifications
o Structuring Survey Questions o QFD Toolset
o The Degree of Uncertainty in Sampling o Exercises and Quiz
o Guideline for Margin of Error

Session 4: Define III – Mapping the Process (5.40 Hours)

o Drawing a Process Picture o Value-Added Flow Charts
o Process Thinking o Spaghetti Charts
o The Source of Value o Takt Time
o The Source of Value: Gemba o Value Stream Mapping Toolset
o Process Mapping - Overview o Define Tollgate – Progress Review
o Process Mapping (SIPOC)Toolset o Exercises and Quiz
o Flow Charts

Session 5: Measure I – Measurements and Basic Statistics (6.00 Hours)

o Measurements and Basic Statistics o Graphical Summaries
o Business Problem Solving o Pareto Chart Toolset
o Basic Statistical Terms o Histogram Toolset
o Descriptive and Inferential Statistics o Understanding Variation
o Measurements o Measuring Central Tendency
o Discrete vs. Continuous o Quantifying Process Variability
Measurements o The Normal Distribution
o Measurement Subjects o Exercises and Quiz

Session 6: Measure II – Measurement System Analysis (8.55 Hours)

o Measurement System Analysis – o The Requirements of Measurement
Introduction Systems
o Measurement as a Process o Variable MSA – Gage R & R
o Cause & Effect Matrix Toolset o MSA Graphing
o The Analysis of Measurement Systems o Attribute Measurement System
Analysis

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Session 6: Measure II – Measurement System Analysis (Continued)
o Calibration of Measurement Systems o Derivative Performance Metrics –
o Collecting Data Rolled Throughput Yield
o Developing a Sampling Plan o Calculating the Sigma Level – Toolset
o Baseline Performance o Exercises and Quiz
o Derivative Performance Metrics –
Throughput Yield

Session 7: Measure III – Charting Process Behavior (9.45 Hours)

o Introduction – Charting Process o Rational Subgrouping Toolset
Behavior o X and Moving Range Charts - Toolset
o Trend Chart Toolset o Attribute Control Chart Toolset
o SPC - Introduction and Background o X-bar and R Chart Toolset
o SPC - Introduction to Control Charts o Process Capability Toolset
o SPC - Control Chart Limits o The Sigma Level Revisited
o SPC - More On Control Limits o Measure Tollgate - Progress Review
o Implementing SPC o Exercises and Quiz
o SPC Chart Selection

Session 8: Analyze I – Identifying Potential Root Causes (10.15 Hours)

o Analyze I - Introduction o Box Plots Toolset
o Finding The Root Cause o Scatter Plot Toolset
o Cause & Effect Diagram Toolset o Correlation and Regression Analysis
o Alternative To The Cause & Effect o Multiple Regression Toolset
Diagram o Binary Logistic Regression Toolset
o 5-Why, 1-How o Factors In Determining Sample Size
o A Combination of 5-Why, Pareto, and o Estimating Population Mean
Trend Charts o Exercises and Quiz

Session 9: Analyze II – Hypothesis Testing (22.40 Hours)

o Analyze II - Introduction o Power Analysis - Factors
o Introduction to Hypothesis Testing o Hypothesis Testing
o The Process On Trial o Confidence Intervals
o The Hypothesis - Accept or Reject? o Treatment Comparisons – Control
o Types of Error Charts
o Power Analysis

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Session 9: Analyze II – Hypothesis Testing (Continued)
o Comparing One Proportion to a o Comparing One Variance to a Std. -
Standard Chi-Square
o Comparing Two Proportions Toolset o Comparing Two Variances - F-test
o Comparing Multiple Proportions - Chi- Toolset
Square o Parametric vs. Non Parametric Tests
o Comparing One Mean to a Standard - o Non Parametric Toolset
t-test o Hypothesis Testing Learning Lab
o Comparing Two Means - t-test Toolset o Exercises and Quiz
o Comparing Multiple Means - ANOVA
/F-test Toolset

Session 10: Analyze III – Design of Experiments (36.20 Hours)

o Design of Experiments - Introduction o Two Level Fractional Factorial Toolset
o Design of Experiments - History o General Factorial toolset
o Design of Experiments - Components o DOE Power and Sample Size
o Design of Experiments - Principles o Designing An Experiment To Save The
o Design of Experiments - Purpose Kingdom
o Design of Experiments - Process o Better Pizza Through Design of
o Design of Experiments – Guidelines Experiments
o Selecting the Right Design o Designing Experiments to Sell More
o Blocking Coffee
o Blocking and Tackling o Brewing Better Beer Using DOE
o Faster Deliveries Through o Additional Subjects
Experimentation o Analyze Tollgate - Progress Review
o Beyond One-Factor Experiments o Design of Experiments Exercises and
o Two Level Full Factorial Toolset Quiz

Session 11: Improve (12.75 Hours)

o Improve o The A3 One-Page Report
o Design for Six Sigma (DFSS) o Continuous Flow Toolset
o Benchmarking o Quick Changeover Toolset
o Brainstorming o Cellular Processing Toolset
o Narrowing Down The List of Ideas o Leveling Production (Heijunks)
o FMEA Toolset o The Theory of Constraints (TOC)
o Error-proofing Toolset
o Prioritizing and Selecting a Solution o Pull System Overview

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Session 11: Improve (Continued)
o Pull Scheduling o Piloting a Solution
o Core Process Pull Toolset o System Dynamics Toolset
o Replenishment Pull Overview o Improve Tollgate – Progress Review
o Kaizen Toolset o Exercises and Quiz
o Corrective Action Matrix
Session 12: Control (6.70 Hours)
o Control o TPM Core Elements
o Control Charts Revisited o TPM Maintenance Activities
o The Process Control Plan o Best Practices and Lessons Learned
o More On FMEA o Standardized Work - Documenting
o Visual Management Process Change
o 5-S Approach o Ending the Project
o CHECK Process o Control Tollgate– Progress Review
o Total Productive Maintenance o Exercises and Quiz
o TPM Objectives & Benefits o Course Completion
o TPM Metrics o The Lean Six Sigma Journey

Updated on: 2/14/2019

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