Lean Six Sigma Black Belt Certification Training - Lesson 1
What is Quality (Introduction)

• Understand the history of quality
• Gathering the voice of the customer
• Garvin's five definitions of quality
• Definitions of quality from quality gurus
• Differences in quality between products and services

Lean Six Sigma Black Belt Certification Training - Lesson 2
Enterprise-wide View (Introduction)

• Understand the history of continuous improvement
• Six Sigma as a Value
• Six Sigma as a Measure
• Six Sigma as a Metric
• Six Sigma Approach
• Six Sigma Process
• Six Sigma System
• Benefits of Six Sigma

Lean Six Sigma Black Belt Certification Training - Lesson 3
Lean (Introduction)
Understand the history of Lean and the value it brings to an organisation
The philosophy and goals of Lean Manufacturing
Understand how Lean integrates with Six Sigma
Business processes and systems

Lean Six Sigma Black Belt Certification Training - Lesson 4
Leadership (Introduction)

• Leadership responsibilities
• Organisational roadblocks and how to overcome them
• Change management
• Six sigma projects and Kaizen events

Lean Six Sigma Black Belt Certification Training - Lesson 5
Roles and Responsibilities (Introduction)

• Key six sigma players
• Player responsibilities
• Team stages
• Team communication

Lean Six Sigma Black Belt Certification Training - Lesson 6
Six Sigma Important Stakeholders (Define Phase)

• Describe the stakeholders in Six Sigma projects
• Understand how the changeover to Six Sigma implementation affects stakeholders
• Undertake stakeholder analysis

Lean Six Sigma Black Belt Certification Training - Lesson 7
Critical X Requirements (Define Phase)

• Understand the Critical to "X" concept
• Describe categories of performance metrics
• Aligning projects with CTX requirements

Lean Six Sigma Black Belt Certification Training - Lesson 8
Benchmarking (Define Phase)

• Understand the the framework for competitor analysis
• Types of benchmarking
• Steps in benchmarking

Lean Six Sigma Black Belt Certification Training - Lesson 9
Business Performance Measures (Define Phase)

• Balanced scorecard
• Key performance indicators
• Customer loyalty

Lean Six Sigma Black Belt Certification Training - Lesson 10
Financial Measures (Define Phase)

• Understand different financial measures
• Apply net present value calculation (NPV)
• Cost benefit analysis
• Hard and soft financial benefits

Lean Six Sigma Black Belt Certification Training - Lesson 11
Voice of Customer and satisfaction levels (Define Phase)

• Understand the Voice of Customer concept
• Apply procedure to comprehend the VOC
• Questions to identify what is critical to customer satisfaction
• Understand the Kano model
• Juran's customer needs

Lean Six Sigma Black Belt Certification Training - Lesson 12
Critical to Quality Flowdown (Define Phase)

• Understand the definition and purpose of Critical to Quality
• Understand the Critical to Quality steps or flowdown
• Essence of Cost of Poor Quality (COPQ)
• Hard and soft savings

Lean Six Sigma Black Belt Certification Training - Lesson 13
Quality Function Deployment (Define Phase)

• Brief history of QFD
• Questions answered using QFD
• House of quality
• Building the House of Quality

Lean Six Sigma Black Belt Certification Training - Lesson 14
Performance Metrics (Define Phase)

• Explain what performance metrics are and they can be used to measure the effectiveness and efficiency of a process and establish goals for a project’s anticipated outcome
• Explain the difference between process and business metrics
• Know what questions to ask to determine the quality of the performance metrics

Lean Six Sigma Black Belt Certification Training - Lesson 15
Project Charter (Define Phase)

• Understand the purpose of a project charter
• Understand the requirements and the elements of a project charter
• Know how to phrase a problem statement
• Know what questions to ask to determine the quality of the performance metrics

Lean Six Sigma Black Belt Certification Training - Lesson 16
Project Management and Tracking (Define Phase)

• Creation of a project baseline
• Project tracking
• Determine the reason for experimenting
• Structure and characteristics of Work Breakdown Structure (WBS)
• Purpose and examples on Gantt Chart

Lean Six Sigma Black Belt Certification Training - Lesson 17
Wrap Up & Action Items (Define Phase)

Lean Six Sigma Black Belt Certification Training - Lesson 18
Processes and Process Characteristics (Measure Phase)
LSS Black Belt Measure Phase - The Measure Phase of the DMAIC methodology is constructed to introduce important Lean Six Sigma tools for characterising your business issues.

• Define a process
• Explain different types of processes
• Explain different process characteristics

Lean Six Sigma Black Belt Certification Training - Lesson 19
Process Maps and Flow Chart (Measure Phase)

• Understand how to create a process map
• Understand the different types of process maps
• Describe process flow metrics and how they are used

Lean Six Sigma Black Belt Certification Training - Lesson 20
SIPOC (Measure Phase)

• Understand meaning and importance of SIPOC diagram
• Understand when to use SIPOC
• Create a SIPOC diagram

Lean Six Sigma Black Belt Certification Training - Lesson 21
Data Types and Measurement Scales (Measure Phase)

• Understand how to choose different data collection methods
• Know how to use check sheets and when to use different types of check sheets
• Understand the advantages and disadvantages of automated gauging
• Know how to code data and the advantages and disadvantages of coding data
• Understand the concepts of data integrity and accuracy

Lean Six Sigma Black Belt Certification Training - Lesson 22
Data Collection (Measure Phase)

• Understand how to choose different data collection methods
• Know how to use check sheets and when to use different types of check sheets
• Understand the advantages and disadvantages of automated gauging
• Know how to code data and the advantages and disadvantages of coding data
• Understand the concepts of data integrity and accuracy

Lean Six Sigma Black Belt Certification Training - Lesson 23
Sampling Strategies (Measure Phase)

• Understand the concept of sampling and the different types of sampling strategies
• Apply probability sampling strategies
• Apply non-probability sampling strategies
• Know how to calculate and determine sample size for continuous and discrete data

Lean Six Sigma Black Belt Certification Training - Lesson 24
Fishbone Diagram (Measure Phase)

• Understand the purpose and meaning of the Ishikawa or Fishbone diagram
• Apply the Fishbone diagram
• Apply non-probability sampling strategies
• Know how to calculate and determine sample size for continuous and discrete data

Lean Six Sigma Black Belt Certification Training - Lesson 25
Relational Matrix /Prioritisation Matrix (Measure Phase)

• Understand that a relational matrix is a tool used to measure which of the input variables has the greatest effect on output
• Know when and how to use a relational matrix
• Understand the differences between the X-T matrix and the Quality Function Deployment (QFD)

Lean Six Sigma Black Belt Certification Training - Lesson 26
Basic Statistics (Measure Phase Module)

• Explain the various statistics used to express location and spread of data
• Describe the characteristics of a Normal Distribution
• Explain the measures of dispersion
• Understand and use measures of symmetry
• Explain the Central Limit Theory
• Explain frequency distribution

Lean Six Sigma Black Belt Certification Training - Lesson 27
Graphical Methods (Measure Phase)

• Understand how to construct histograms and differences in distribution shape
• Construct a histogram using Minitab
• Construct a stem and leaf plot
• Construct a box plot
• Construct a run chart
• Explain the significance of P values in relation to hypotheses
• Compare graphical methods and decide which is best to use

Lean Six Sigma Black Belt Certification Training - Lesson 28
Inferential Statistics (Measure Phase)

• Steps involved in analytical statistics
• The Rules of Probability
• Combinations and Permutations in probability
• Probability distribution
• Discrete and continuous distributions

Lean Six Sigma Black Belt Certification Training - Lesson 29
Gauge R and R (Measure Phase)

• Understand the concept of gauge repeatability and reproducibility
• Understand the concepts of accuracy, precision, linearity, stability and bias
• Apply Gauge R and R
• Apply Gauge R and R regression analysis

Lean Six Sigma Black Belt Certification Training - Lesson 30
Process Capability Analysis (Measure Phase)

• Understand causes of variation
• Estimate Capability for Continuous Data
• Describe the impact of Non-normal Data on the analysis presented in this module for Continuous Capability
• Estimate Capability for Attribute Data

Lean Six Sigma Black Belt Certification Training - Lesson 31
Wrap Up & Action Items (Measure Phase)

Lean Six Sigma Black Belt Certification Training - Lesson 32
Graph and Data Analysis (Analyse Phase)

• Construct a scatter diagram
• Understand correlation and regression analysis
• Apply the method of least square
• Apply a simple linear regression model
• Apply multiple linear regression analysis

Lean Six Sigma Black Belt Certification Training - Lesson 33
Multi-Vari Analysis (Analyse Phase)

• Perform a Multi-Vari Analysis
• Interpret and a Multi-Vari Graph
• Identify when a Multi-Vari Analysis is applicable

Lean Six Sigma Black Belt Certification Training - Lesson 34
Intro to Hypothesis Testing (Analyse Phase)

• Articulate the purpose of Hypothesis Testing
• Explain the concepts of the Central Tendency
• Be familiar with the types of Hypothesis Tests
• Statistical inference
• Understand the concepts between statistical and practical significance
• Calculate point and interval estimations
• Calculate margin of error and sample size
• Calculate confidence intervals

Lean Six Sigma Black Belt Certification Training - Lesson 35
Hypothesis Testing Normal Data (Analyse Phase)

• Determine appropriate sample sizes for testing Means
• Conduct various Hypothesis Tests for Means
• Properly Analyse Results
• Be able to conduct Hypothesis Testing of Variances
• Understand how to Analyse Hypothesis Testing Results

Lean Six Sigma Black Belt Certification Training - Lesson 36
Hypothesis Testing Non-Normal Data (Analyse Phase )

• Conduct Hypothesis Testing for equal variance
• Conduct Hypothesis Testing for Medians
• Analyse and interpret the results
• Calculate and explain test for proportions
• Calculate and explain contingency tests

Lean Six Sigma Black Belt Certification Training - Lesson 37
Pareto Charts (Analyse Phase)

• Explain the objectives of a Pareto chart
• Construct a Pareto chart
• Test proportion = specified value
• Test if two proportions are equal

Lean Six Sigma Black Belt Certification Training - Lesson 38
Failure Mode and Effects Analysis (Analyse Phase)

• Explain the of conducting FMEA and its various elements
• Explain and calculate Risk Priority Number
• Understand procedures involved in conducting FMEA
• Understand differences of design and process FMEA
• Explain advantages and disadvantages of conducting FMEA

Lean Six Sigma Black Belt Certification Training - Lesson 39
Non-Value Added Activities (Analyse Phase)

• Understand the seven types of process waste
• Understand the difference between value and non-value added activities
• Identify non-value added activities from process maps

Lean Six Sigma Black Belt Certification Training - Lesson 40
Value Stream Mapping (Analyse Phase)

• Understand VSM process and symbols used
• Create a Value Stream Map
• Understand the difference between cycle time and takt time
• Know when to use Lean Systems
• Construct a spaghetti chart
• Outline the benefits of VSM

Lean Six Sigma Black Belt Certification Training - Lesson 41
Wrap Up & Action Items (Analyse Phase)

Lean Six Sigma Black Belt Certification Training - Lesson 42
Generate New and Re-usedSolutions (Improve Phase)

• LSS Black Belt Improve Phase - The Improve Phase of the DMAIC methodology is constructed to introduce important Lean Six Sigma tools for properly controlling solutions.
• Generate solution ideas
• Apply six thinking hats to evaluate solutions
• Understand the role of bench-marking solutions
• Understand the concept of process entitlement

Lean Six Sigma Black Belt Certification Training - Lesson 43
5S (Improve Phase)

• Understand the 5 concepts in the 5S model
• Understand the effect of 5S on improvements

Lean Six Sigma Black Belt Certification Training - Lesson 44
Evaluate and select top solution (Improvement Phase)

• Understand the approach to design and implement a solution
• Prepare process maps that reflect the desired state
• Understand the concept of poka-yoke (mistake proofing)
• Understand the steps to pilot the top solution

Lean Six Sigma Black Belt Certification Training - Lesson 45
Designing Experiments (Improve Phase)

• Understand the concept of experiment design and the terminology
• Nomenclature for factorial experiments
• Understand different types of design
• Understand the difference between balanced and orthogonal designs and the role of centre points
• Conduct two-way ANOVA experiments with and without replicas
• Analyse factorial experiments
• Create a Full and a Fractional Factorial Design

Lean Six Sigma Black Belt Certification Training - Lesson 46
Kaizen and Kanban and Theory of Constraints (Improvement Phase)

• Understand the concept of Kaizen and Demming cycle and a Kaizen event
• Understand the concept of Kanban and the Push vs Pull system of production
• Know how to create strategic buffer
• Understand the Theory of Constraints and the five focusing steps

Lean Six Sigma Black Belt Certification Training - Lesson 47
Single Minute Exchange of Die (Improve Phase)

• Understand the objectives of SMED
• Understand the techniques of implementing and the effects of SMED

Lean Six Sigma Black Belt Certification Training - Lesson 48
Risk Analysis and Mitigation (Improve Phase)

• Understand the purpose of a risk assessment tool
• Understand how to conduct a SWOT and PEST analysis
• Understand the concept of poka-yoke (mistake proofing)
• Understand the steps to pilot the top solution

Lean Six Sigma Black Belt Certification Training - Lesson 49
Total Productive Maintenance (Improve Phase)

• Explain the concept of TPM
• Understand the 8 pillars of TPM
• Explain the benefits of TPM

Lean Six Sigma Black Belt Certification Training - Lesson 50
Lean Six Sigma Logistics (Improve Phase)

• Understand how Lean Six Sigma techniques can be used to optimise the performance of an organisation’s logistics network
• Know how to implement Lean Logistics and how they can reduce inventory maintenance costs

Lean Six Sigma Black Belt Certification Training - Lesson 51
Wrap Up & Action Items (Improve Phase)

Lean Six Sigma Black Belt Certification Training - Lesson 52
Statistical Process Control - SPC (Control Phase )

• Describe the elements of an SPC Chart and the purposes of SPC
• Understand how SPC ranks in defect prevention
• Describe the special cause detection rules
• Design subgroups if needed for SPC usage
• Understand the differences between Attribute and Continuous Control Charts
• Create an I-MR control chart
• Create an X-bar R chart
• Create an X-bar S chart
• Create P and Np charts
• Create a U chart
• Create time-weighted charts
• Explain the purpose of a Visual Factory

Lean Six Sigma Black Belt Certification Training - Lesson 53
Maintain Controls (Control Phase)

• Understand the purpose of conducting a cost benefit analysis
• Understand the purpose of a Control Plan
• Understand the purpose of a documentation plan
• Understand the concept of lessons learned

Lean Six Sigma Black Belt Certification Training - Lesson 54
Wrap Up & Action Items (Control Phase)