LEAN SIX SIGMA BLACK BELT AGENDA
1.0 Define Phase
1.1 The Basics of Six Sigma
- 1.1.1 Meanings of Six Sigma
- 1.1.2 General History of Six Sigma & Continuous Improvement
- 1.1.3 Deliverables of a Lean Six Sigma Project
- 1.1.4 The Problem Solving Strategy Y = f(x)
- 1.1.5 Voice of the Customer, Business and Employee
- 1.1.6 Six Sigma Roles & Responsibilities
1.2 The Fundamentals of Six Sigma
- 1.2.1 Defining a Process
- 1.2.2 Critical to Quality Characteristics (CTQ’s)
- 1.2.3 Cost of Poor Quality (COPQ)
- 1.2.4 Pareto Analysis (80:20 rule)
- 1.2.5 Basic Six Sigma Metrics
- a. including DPU, DPMO, FTY, RTY Cycle Time; deriving these metrics
1.3 Selecting Lean Six Sigma Projects
- 1.3.1 Building a Business Case & Project Charter
- 1.3.2 Developing Project Metrics
- 1.3.3 Financial Evaluation & Benefits Capture
1.4 The Lean Enterprise
- 1.4.1 Understanding Lean
- 1.4.2 The History of Lean
- 1.4.3 Lean & Six Sigma
- 1.4.4 The Seven Elements of Waste
- a. Overproduction, Correction, Inventory, Motion, Overprocessing, Conveyance, Waiting.
- 1.4.5 5S
- a. Straighten, Shine, Standardize, Self-Discipline, Sort
2.0 Measure Phase
2.1 Process Definition
- 2.1.1 Cause & Effect / Fishbone Diagrams
- 2.1.2 Process Mapping, SIPOC, Value Stream Map
- 2.1.3 X-Y Diagram
- 2.1.4 Failure Modes & Effects Analysis (FMEA)
2.2 Six Sigma Statistics
- 2.2.1 Basic Statistics
- 2.2.2 Descriptive Statistics
- 2.2.3 Normal Distributions & Normality
- 2.2.4 Graphical Analysis
2.3 Measurement System Analysis
- 2.3.1 Precision & Accuracy
- 2.3.2 Bias, Linearity & Stability
- 2.3.3 Gage Repeatability & Reproducibility
- 2.3.4 Variable & Attribute MSA
2.4 Process Capability
- 2.4.1 Capability Analysis
- 2.4.2 Concept of Stability
- 2.4.3 Attribute & Discrete Capability
- 2.4.4 Monitoring Techniques
3.0 Analyze Phase
3.1 Patterns of Variation
- 3.1.1 Multi-Vari Analysis
- 3.1.2 Classes of Distributions
3.2 Inferential Statistics
- 3.2.1 Understanding Inference
- 3.2.2 Sampling Techniques & Uses
- 3.2.3 Central Limit Theorem
3.3 Hypothesis Testing
- 3.3.1 General Concepts & Goals of Hypothesis Testing
- 3.3.2 Significance; Practical vs. Statistical
- 3.3.3 Risk; Alpha & Beta
- 3.3.4 Types of Hypothesis Test
3.4 Hypothesis Testing with Normal Data
- 3.4.1 1 & 2 sample t-tests
- 3.4.2 1 sample variance
- 3.4.3 One Way ANOVA
- a. Including Tests of Equal Variance, Normality Testing and Sample Size calculation, performing tests and interpreting results.
3.5 Hypothesis Testing with Non-Normal Data
- 3.5.1 Mann-Whitney
- 3.5.2 Kruskal-Wallis
- 3.5.3 Mood’s Median
- 3.5.4 Friedman
- 3.5.5 1 Sample Sign
- 3.5.6 1 Sample Wilcoxon
- 3.5.7 One and Two Sample Proportion
- 3.5.8 Chi-Squared (Contingency Tables)
- a. Including Tests of Equal Variance, Normality Testing and Sample Size calculation, performing tests and interpreting results.
4.0 Improve Phase
4.1 Simple Linear Regression
- 4.1.1 Correlation
- 4.1.2 Regression Equations
- 4.1.3 Residuals Analysis
4.2 Multiple Regression Analysis
- 4.2.1 Non- Linear Regression
- 4.2.2 Multiple Linear Regression
- 4.2.3 Confidence & Prediction Intervals
- 4.2.4 Residuals Analysis
- 4.2.5 Data Transformation, Box Cox
4.3 Designed Experiments
- 4.3.1 Experiment Objectives
- 4.3.2 Experimental Methods
- 4.3.3 Experiment Design Considerations
4.4 Full Factorial Experiments
- 4.4.1 2k Full Factorial Designs
- 4.4.2 Linear & Quadratic Mathematical Models
- 4.4.3 Balanced & Orthogonal Designs
- 4.4.4 Fit, Diagnose Model and Center Points
4.5 Fractional Factorial Experiments
- 4.5.1 Designs
- 4.5.2 Confounding Effects
- 4.5.3 Experimental Resolution
5.0 Improve Phase
5.1 Lean Controls
- 5.1.1 Control Methods for 5S
- 5.1.2 Kanban
- 5.1.3 Poka-Yoke (Mistake Proofing)
5.2 Statistical Process Control (SPC)
- 5.2.1 Data Collection for SPC
- 5.2.2 I-MR Chart
- 5.2.3 Xbar-R Chart
- 5.2.4 U Chart
- 5.2.5 P Chart
- 5.2.6 NP Chart
- 5.2.7 Xbar-S Chart
- 5.2.8 CuSum Chart
- 5.2.9 EWMA Chart
- 5.2.10 Control Methods
- 5.2.11 Control Chart Anatomy
- 5.2.12 Subgroups, Impact of Variation, Frequency of Sampling
- 5.2.13 Center Line & Control Limit Calculations
5.3 Six Sigma Control Plans
- 5.3.1 Cost Benefit Analysis
- 5.3.2 Elements of the Control Plan
- 5.3.3 Elements of the Response Plan