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Applied LEAN Six Sigma Black Belt

This course is targeted toward developing Six Sigma process improvement project leaders.  It provides a background on the LEAN and Six Sigma methodologies and covers the tools and techniques necessary for implementing a successful process improvement culture.  As prework, students will be required identify and to bring a “live” process improvement project and supporting data to class where we will develop a clear project definition, conduct data analysis using tools that require basic Excel knowledge and get a great start on an actual project.  Upon completion of the course, an exam and the project, students will qualify for the Applied LEAN Six Sigma Black Belt certification.  A project template will be provided for project documentation/ submission.  Students may take up to six months to submit their completed project.  Each day the student will have homework to be presented at the beginning of the next session.

Session One
• Introduction to Six Sigma Methodology
• History of Six Sigma
• How is Six Sigma different from Total Quality or other Quality programs?
• What is Six Sigma?  Key Definitions and Roles and Responsibilities
• Value of Six Sigma
• How does it work?
• Key elements of Six Sigma
• Approaches to Six Sigma
• LEAN concepts and tools
• Value stream mapping overview
• The project selection process – when to use each approach
• Owners and stakeholders – the Voice of the Customer
• Identifying and analyzing customers
• Using the SIPOC
• Process elements – define and describe process components and boundaries
• Introduction to DMAIC (Define-Measure-Analyze-Improve-Control)

Session Two – Define
• Presentations – project overview and SIPOC
• Developing the project charter and problem statement
• The Seven Basic Quality Tools
• Methods for collecting customer feedback
• Analyzing customer feedback
• Translating feedback into requirements – CTQ (Critical to Quality)
• Defining the project scope
• Identifying value-added and non-value added activities
• Defining team roles and responsibilities for a Six Sigma project team
• Team stages and dynamics
• Project planning
• Project risk analysis
• Communication techniques and documentation
• Defining key project metrics
• Team tools
• Process modeling – “as is”

Session Three – Measure
• Presentations – Project Charter, Problem Statement and “As is” process model
• Calculating process performance metrics – COPQ, DPMO, Yield
• Collecting and summarizing data
• Types of data and measurement scales
• Data collection methods
• Assuring data accuracy and integrity
• Populations and samples – when to use each
• Central limit theorem and sampling distribution
• Measures of dispersion and central tendency
• Probability concepts and distributions
• Measurement system analysis
• Process capability studies
• Process performance vs. specification
• Computing the Sigma level
• Applying sampling plans

Session Four – Analyze
• Presentations – Data Collection Plans
• Leading a Kaizan event
• Interpreting diagrams
• Process capability  and performance indices
• Short-term vs. long-term capability
• Basics of hypothesis testing
• Tests for means, variances and proportions
• Paired-comparison tests
• Analysis of variance
• Theory of constraints
• Design for Six Sigma (DFSS) in the organization
• Road maps for DFSS
• Introduction to FMEA

Session Five – Improve and Control
• Presentations – Analysis results
• Introduction to Improve
• Design of experiments
• DOE Terms
• Interpreting main effects
• Implement and validate solutions
• Statistical Process Control – objectives and benefits
• Validate Savings
• COPQ Review
• Control Overview
• Selection and application of control charts
• Analysis of control charts
• Control Plan Key Deliverables
• Control Plan Components
• Transition Plan Execution
• Project Close Out Process
• Exam and Review
• Wrap up