Course Description

BLACKBELT BODY OF KNOWLEDGE:

MODULE-1: INTRODUCTION

Fundamentals of Six Sigma and lean methodologies, Six Sigma, lean, and continuous improvement methodologies, Relationships among business systems and processes, Strategic planning and deployment for initiatives

• Leadership: Roles and responsibilities, Organizational roadblocks, and change management
• Organizational Process Management & Measures: Stakeholder analysis, Benchmarking, Performance measures, Financial measures
• Team Management
• Team Formation:Team types and constraints, Team roles and responsibilities, Team member selection criteria, Team success factors
• Team Facilitation: Motivational techniques, Team stages of development: Team communication, Team leadership models,
• Team Dynamics: Group behaviors, Meeting management, Team decision-making methods
• Team Training:Needs assessment, Delivery, Evaluation

MODULE-2: DEFINE PHASE

• Voice of the Customer: Customer Identification, Customer data collection, Customer requirements
• Business Case and Project Charter: Business case, Problem statement, Project scope, Goals and objectives, Project performance measurements, Project charter review
• Project Management Tools: Gantt charts, Toll-gate reviews, Work breakdown structure (WBS), RACI model
• Analytical Tools: Affinity diagrams, Tree diagrams, Matrix Diagrams, Prioritization Matrices, Activity network diagrams

MODULE-3: MEASURE PHASE

• Process Characteristics: Process flow metrics, Process analysis tools
• Data Collection: Types of data, Measurement scales, Sampling, Data collection plans, and methods
• Measurement Systems: Measurement system analysis (MSA), Measurement systems across the organization, Metrology
• Basic Statistics

Basic statistical terms, Central limit theorem, Descriptive statistics, Graphical methods, Valid statistical conclusions

• Probability

Basic concepts, Distributions

• Process Capability

Process capability indices, Process performance indices, General process capability studies, Process capability for attributes data, Process capability for non-normal data, Process performance vs. specification, Short-term and long-term capability

MODULE-4: ANALYZE PHASE

• Measuring and Modeling Relationships Between Variables:

The correlation coefficient, Linear regression, and Multivariate tools

• Hypothesis Testing: Terminology, Statistical vs. practical significance, Sample size, Tests for means, variances, and proportions, Analysis of variance (ANOVA), Goodness-of-fit (chi-square) tests, Contingency tables, Nonparametric tests
• Failure Mode and Effects Analysis (FMEA)
• Other Analysis Tools: Gap Analysis, Root Cause Analysis, Waste Analysis

MODULE-5: IMPROVE PHASE

Terminology, Design principles, Planning experiments, One-factor experiments, Two-level fractional factorial experiments, Full factorial experiments

• Lean Methods

Waste elimination, Cycle-time reduction, Kaizen, TOC, OEE and techniques, Pilot & Implementation

MODULE-6: CONTROL PHASE

Objectives, Selection of variables, Rational subgrouping, Control chart selection, Control chart analysis

• Other Controls: TPM, Visual controls,
• Maintain Controls: Control plan
• Sustain Improvements: Lessons learned, Documentation, Training for process owners and staff, Ongoing evaluation

MODULE-7: DESIGN FOR SIX SIGMA

• Common DFSS Methodologies, Design for X (DFX), Robust Designs

SAMPLE CERTIFICATE