Advanced Six Sigma Black Belt

Introduction:

Lean focuses on eliminating waste, while Six Sigma aims to meet customer needs and eradicate defects in processes. This Six Sigma Black Belt training integrates both Lean and Six Sigma methodologies into one comprehensive program.

Effective management of this Six Sigma Black Belt program will provide participants with a thorough understanding of Lean Six Sigma theory, elements, and implementation. Participants will gain the expertise needed to apply various analytical tools to define, measure, analyze, improve, and control improvement processes within their organizations.

Objectives:

By the end of this Six Sigma Black Belt course, participants will be able to:

• Define demand-based setups.
• Develop lean process maps.
• Integrate Lean principles into business processes.
• Decrease cycle time by eliminating unavoidable wait times.
• Utilize statistical methods for data analysis and critical thinking.
• Manage processes and projects to foster a culture of continuous improvement.
• Understand factors affecting process quality and identify areas for improvement to enhance customer satisfaction.
• Implement necessary changes.
• Reduce variability to improve existing processes.
• Measure and enhance critical process elements to boost quality.

Training Methodology:

• Case Studies
• Simulation Exercises
• Workshops
• Interactive Lectures
• Data Analysis Labs
• Group Projects
• Role-play
• Problem-solving exercises

Course Outline:

Unit 1: Introductory Skills Course in Lean and Six Sigma

• Lean and Six Sigma concepts
• Historical evolution of Six Sigma and Lean
• Lean principles and Black Belt tools
• Overview of DMAIC methodology
• Define Phase: Project current state and Project Charter
• Understanding critical elements of quality and efficiency
• Roles and responsibilities of a Six Sigma Black Belt
• Overview of process improvement models
• Value-added advantages of combining Lean and Six Sigma
• Cost saving and elimination of non-value-added activities

Unit 2: Measure Phase

• Methods of data collection and measurement system analysis (MSA)
• Business process modeling and Lean implementation
• Measurement and MSA in Six Sigma
• Basic statistics and probability for Six Sigma
• Correlation research in Six Sigma
• Proper data collection methods
• Determination and analysis of key performance measures (KPM)
• Statistical software applications
• Data protection objectives
• Evaluating variation and measurement errors

Unit 3: Contemplation Phase and Lean Tools

• Statistical tests and problem definition in Six Sigma
• Design of Experiments (DOE) in Six Sigma
• Use of Lean tools and value stream mapping
• Kaizen and process improvement activities
• Addressing advanced problems in Six Sigma
• Identifying detailed processes and causes of variation or defects
• Fishbone diagrams and the 5 Whys technique
• Assessing capability
• Preparing action plans for process improvement

Unit 4: Improve and Control Phases

• Implementing Lean solutions and error-proofing
• Change management and solution roll-out
• SPC and control plan development
• Tracking, controlling, and maintaining improvements
• Project closure and Six Sigma Black Belt course process
• Creating and evaluating improvement priorities
• Controlling and reducing process variation
• Using control charts and monitoring systems
• Sustaining long-term improvements
• Final project completion and presentation

Unit 5: Advanced Six Sigma Black Belt Concepts

• Team dynamics and leadership in Six Sigma initiatives
• Aligning Six Sigma with strategic plans
• Cost analysis and cost-effectiveness analysis
• Risk management
• Frameworks for Lean Six Sigma in service and manufacturing
• New product development and advanced DFSS (Design for Six Sigma)
• Management of supply chains with Six Sigma
• Integrating Six Sigma with other management systems
• Establishing a culture of continuous improvement
• Workplace ethics in Six Sigma projects and management