Lean Six Sigma Black Belt Certification Training

Unit 1: Introduction to Six Sigma

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• What is Quality?
• Enterprise-Wide view
• Leadership
• Six Sigma Roles and Responsibilities
• Team Formation
• Team Facilitation
• Team Dynamics
• Time Management for Teams
• Team Decision Making Tools
• Seven Management and Planning Tools
• Team Performance Evaluation and Reports

Unit 2: Define Phase

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• Important Stakeholders
• Impact on Stakeholders
• Critical to Quality Requirements
• Critical to Cost Requirements
• Critical to Process Requirements
• Critical to Safety Requirements
• Critical to Delivery Requirements
• Types of Benchmarking
• Business Performance Measures
• Financial Measures
• Voice of Customer (VOC)
• Kano Customer Satisfaction Levels
• Market Research
• Critical to Quality Flow Down
• Quality Function Deployment (QFD)
• Process, Performance and Business Metrics
• Project Charter and Performance Measures
• Charter Negotiation
• Project Management Plan
• Project Tracking

Unit 3: Measure Phase

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• Process Characteristics
• Process Flow Metrics
• Uses of Process Flow Metrics
• Process Maps and Flow Chart
• Understanding SIPOC
• Data Type and Measurement Scale
• Data Collection
• Sampling Strategies
• Fishbone Diagram
• Relational Matrix / Prioritization Matrix
• Basic Statistics
• Analytical Statistics
• Gauge R and R
• Process capability analysis

Unit 4: Analyse Phase

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• Correlation and Regression Analysis
• Testing of Hypothesis
• Failure Mode and Effects Analysis (FMEA)
• Procedures Involved in Conducting FEMA
• Understanding GAP Analysis
• The Five Whys
• Pareto Charts
• Tree Diagram
• Non-Value Added Activities
• Cost of Quality (COQ)

Unit 5: Improve Phase

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• Design of Experiments (DOE)
• Full and Functional Factorial
• Analysing Factorial Experiments
• Poka-yoke (Mistake Proofing)
• Understanding 5S Concept
• Single Minute Exchange of Die (SMED)
• Continuous Flow Manufacturing
• Understanding Kaizen
• The Deming Improvement Cycle used for Kaizen
• Working Process of Kaizen
• Understanding Kanban
• Theory of Constraints
• Risk Analysis and Mitigation
• Feasibility Study
• Risk Analysis
• SWOT Analysis
• PEST Analysis

Unit 6: Control Phase

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• Statistical Process Control
• Components of a Control Chart
• Rational Sub Grouping
• Visual factory
• Total Productive Maintenance (TPM)
• Maintain Controls
• Measurement System reanalysis
• Creating a Control Plan
• Sustaining Improvements
• Training Plan Deployment

Unit 7: Design of Six Sigma (DFSS)

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• Understanding DFSS Technologies
• Design for Cost
• Design for Manufacturability
• Design for Test
• design for Maintainability
• Robust Product Design
• Noise Strategy
• Tolerance design
• Statistical Tolerance
• Special Design Tools
• Understanding TRIZ
• Pugh Analysis

Unit 8: Lean Six Sigma

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• The Essentials of Lean
• The Lean Metric Cycle Efficiency
• Finding and Eliminating Time Traps
• Sources of Cost Reduction
• Creating Value Stream Map
• Value Added and Non-Value-Added Activity
• Value Stream Map Tools
• Pull System - Kanban
• Understanding Strategic Buffer
• Calculating Strategic Buffer
• Synchronous and Asynchronous Pull System
• Lean Six Sigma Logistics
• Implementation of Lean Logistics
• Reduction of Inventory Maintenance Costs
• Benefits of Standard Work Operations
• Importance of Visual factory in Operator Work Instructions
• Cycle Time Reduction and Takt Time
• Techniques of Cycle Time Reduction
• Cycle Time vs Takt Time

Unit 9: Case Study

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