Training Agenda: Six Sigma Black Belt Certification
Duration: 120 Hours (15 Days)
Target Audience: Professionals experienced with Six Sigma (Green Belts or equivalent) who want to lead larger projects, mentor other Six Sigma practitioners, and be experts in process improvement.
Objective: To provide participants with the skills, knowledge, and methodologies necessary to lead high-impact Six Sigma projects, utilizing advanced statistical analysis, Lean principles, and leadership techniques.
Day 1: Introduction and Black Belt Role Overview (8 hours)
Registration and Welcome
- Introduction to the Black Belt course objectives and structure
- Participant introductions and setting goals
- Review of Green Belt knowledge and how Black Belt builds on it
Break
Six Sigma Overview and Black Belt Role
- Review of Six Sigma methodology and principles
- The role of the Black Belt in project leadership and mentoring
- Differences between Green Belt and Black Belt roles
- Overview of the DMAIC framework for Black Belts
Lunch Break
Project Selection and Leadership
- Criteria for selecting high-impact Six Sigma projects
- Aligning Six Sigma projects with business strategy
- Stakeholder management and leadership skills for Black Belts
- Practical exercise: Identifying potential Black Belt-level projects
Day 2: Define Phase – Advanced Tools
Project Charters and Leadership
- Writing a comprehensive project charter for Black Belt projects
- Establishing SMART goals and critical success factors
- Leadership and team dynamics in Six Sigma project management
Break
Voice of the Customer (VOC) and CTQ
- Advanced techniques for capturing and analyzing the Voice of the Customer
- Translating VOC into Critical to Quality (CTQ) metrics
- Practical exercise: Creating a VOC-to-CTQ matrix
Lunch Break
SIPOC and High-Level Process Mapping
- Creating detailed SIPOC diagrams for complex processes
- Process mapping to understand high-level flows and identify bottlenecks
- Practical exercise: Developing a SIPOC for a real-world problem
Project Management Tools for Black Belts
- Advanced project management techniques (Gantt charts, RACI, risk management)
- Practical exercise: Developing a project management plan for a Six Sigma project
Day 3: Measure Phase – Part 1
Advanced Data Collection and Sampling
- Designing effective data collection plans for complex projects
- Sampling methods and techniques for high-precision data collection
- Practical exercise: Developing a data collection strategy for a project
Break
Measurement System Analysis (MSA) – Advanced
- In-depth Gage R&R analysis
- Attribute Agreement Analysis (AAA) for non-numerical data
- Practical exercise: Conducting advanced MSA and interpreting results
Lunch Break
Process Capability and Benchmarking
- Advanced process capability analysis (Cp, Cpk, Pp, Ppk)
- Benchmarking against industry standards and best practices
- Practical exercise: Capability analysis on real-world data sets
Day 4: Measure Phase – Part 2
Process Mapping and Value Stream Mapping (VSM)
- Detailed process mapping for complex processes
- Introduction to Value Stream Mapping (VSM)
- Identifying waste and inefficiencies in a process
Break
Control Charts – Advanced
- Understanding advanced control charts (e.g., Individuals and Moving Range charts, EWMA)
- Selecting appropriate control charts for different types of data
- Practical exercise: Developing control charts for complex processes
Lunch Break
Process Capability Indices for Non-Normal Data
- Handling non-normal data distributions in capability analysis
- Transformation techniques and alternate capability indices
- Practical exercise: Analyzing non-normal data for process capability
Day 5: Analyze Phase – Part 1
Root Cause Analysis – Advanced Techniques
- Beyond 5 Whys: Advanced tools for root cause analysis
- Using Fishbone (Ishikawa) diagrams with additional analytical techniques
- Practical exercise: Conducting root cause analysis for complex issues
Break
Hypothesis Testing – Advanced
- Understanding hypothesis testing in-depth: p-values, confidence intervals
- One-sample and two-sample t-tests, F-tests, Chi-square tests, and ANOVA
- Practical exercise: Setting up and conducting hypothesis tests using real data
Lunch Break
Regression Analysis – Advanced
- Multiple linear regression and logistic regression
- Identifying significant factors and interactions in process data
- Practical exercise: Performing regression analysis on complex data sets
Day 6: Analyze Phase – Part 2
Design of Experiments (DOE) – Introduction
- The principles of DOE and its application in process improvement
- Factorial designs: Full and fractional factorial designs
- Practical exercise: Setting up a factorial DOE
Break
Failure Mode and Effects Analysis (FMEA) – Advanced
- In-depth FMEA: Prioritizing risks and identifying mitigation strategies
- Practical exercise: Conducting a detailed FMEA on a real-world process
Lunch Break
Advanced Statistical Analysis in Minitab
- Using Minitab for advanced statistical analysis
- Hands-on session: Hypothesis testing, ANOVA, and regression in Minitab
Day 7: Improve Phase – Part 1
Generating and Selecting Solutions
- Techniques for brainstorming and creative problem-solving (TRIZ, SCAMPER)
- Solution prioritization using an Impact/Effort Matrix
- Practical exercise: Generating and selecting solutions for process improvement
Break
Lean Tools in Process Improvement
- Lean techniques: 5S, Kaizen, SMED (Single-Minute Exchange of Die)
- Integrating Lean and Six Sigma for faster improvements
- Practical exercise: Implementing Lean tools in a real-world scenario
Lunch Break
Piloting and Validating Solutions
- Running pilot tests to validate solutions
- Introduction to Design of Experiments (DOE) – Full vs. fractional
- Practical exercise: Running a DOE pilot and interpreting the results
Day 8: Improve Phase – Part 2
Process Simulation and Optimization
- Process simulation tools: Using software to model and optimize processes
- Practical exercise: Simulating process improvements
Break
Mistake Proofing (Poka-Yoke)
- Designing error-proof processes to prevent defects
- Practical exercise: Applying Poka-Yoke techniques to process improvements
Lunch Break
Cost-Benefit Analysis and ROI
- Financial impact analysis of process improvements
- Calculating Return on Investment (ROI) for Six Sigma projects
- Practical exercise: Performing cost-benefit analysis for an improvement
Day 9: Control Phase – Part 1
Sustaining Improvements with Control Plans
- Creating detailed control plans to maintain process improvements
- Standard Operating Procedures (SOPs) and documentation
- Practical exercise: Developing a comprehensive control plan
Break
Statistical Process Control (SPC) – Advanced
- Advanced SPC techniques: EWMA, Cumulative Sum (CUSUM) charts
- Monitoring ongoing process performance with SPC
- Practical exercise: Implementing SPC for a process
Lunch Break
Process Audits and Control Systems
- Developing and implementing process audits for long-term control
- Visual management and control mechanisms for sustained improvements
- Practical exercise: Conducting a mock process audit
Day 10: Control Phase – Part 2
Control Charts for Attribute Data
- P-charts, NP-charts, C-charts, and U-charts for attribute data
- Practical exercise: Creating and interpreting attribute control charts
Break
Documentation and Knowledge Transfer
- Ensuring proper documentation of process improvements
- Creating training materials and transferring knowledge across teams
- Practical exercise: Creating process documentation and training materials
Lunch Break
Finalize Control Plans
- Comprehensive review and finalization of control plans
- Implementing visual management and dashboards
- Practical exercise: Developing a control system for a complex process
Day 11–14: Six Sigma Project Simulation
End-to-End Project Simulation
- Participants work in teams to complete a simulated Six Sigma project from start to finish
- Using DMAIC methodology to solve a real-world problem
- Application of advanced tools learned (e.g., FMEA, DOE, control charts, SPC)
Day 15: Final Case Study Presentation and Certification Exam (8 hours)
Final Project Presentations
- Teams present their final Six Sigma projects
- Feedback from peers and instructors on project implementation and improvements
Lunch Break
Six Sigma Black Belt Certification Exam
- 2-hour written exam covering all aspects of the Black Belt curriculum
- Review and closing discussion