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Lean Six Sigma Boot Camp

Program Summary

    1. 5-day Lean Sigma Yellow Belt Certification (Option: Spread in 2-5 weeks)
    2. Equips participants with the most common tools used in Lean Six Sigma for Manufacturing, BPO, Supply Chain and Services.
    3. Package will include Project Coaching and Toll Gate Reviews.
    4. International Certification from Six Sigma Experts (USA).
    5. Nurture online community of students: Forum for questions, Online coaching, VLOGs by Six Sigma Coach (@sixsigmacoachph),Articles by Coaches and Student

 Course Overview:

We live in a very competitive and global environment. Right before our eyes, businesses evolve and transform, products and services need to satisfy different levels of perfection year after year, as companies pursue customer satisfaction and delight.

Organizations who have acknowledged this, have found the Lean and Six Sigma Program to be an effective, structured, data-driven, way to performance improvement and transformation.

At the forefront of all these, are change agents who will drive, guide, mentor and lead. These leader-experts are called Lean Six Sigma BLACK BELTS. The Black Belt is equipped with a comprehensive knowledge in the application of the tools and methodology of Lean and Six Sigma in various operations, effecting significant reduction in Cost, improvement in Cycle Time, Defect Reduction, Quality improvement, higher efficiency resulting into superior business results.

This program is aimed to train and certify existing Six Sigma Green Belts and Process/Industry Experts in the Lean-Six Sigma Black Belt body of knowledge and its application for various operations or business models.

This 10-day Black Belt training and certification workshop program is spread in of 2-3 months, to enable the qualified candidate absorb, assimilate and apply the tools and methodology. Relevant exercises and multi-media materials will also be used to ensure adequate knowledge absorption and retention.

Course Objectives:

The learning expectations of the participants are the following:

  • Thorough understanding and application of  the Lean-Six Sigma methodology, its process improvement tools and techniques to various operational and business models.
  • Learn how to develop the different work deliverables in each stage of the DMAIC cycle.
  • Learn how to manage major Lean-Six Sigma projects, mentor and train Six Sigma Green Belts/Yellow Belts.
  • Add value to the organization by defining and pursuing relevant projects that will significantly improve Profitability, Quality, Productivity, Cost, Efficiency and Customer Delight.

 

Pre-Requisites:

  • Green Belt Certified
  • Must have one potential Six Sigma project to bring in class.

 

Certification Requirements:

  • Completion of the Black Belt classroom training
  • Pass Certification Exams and Checkpoint Exams (80%)
  • Successful Completion of Exercises and Case Studies during training
  • Completion of One Black Belt Six Sigma project

 

Training Agenda:

DEFINE STAGE  (DAY 1)

    1. Six Sigma Overview
      • What is Six Sigma
      • Six Sigma History
      • Six Sigma Approach Y = f(x)
      • Six Sigma Methodology
      • Roles & Responsibilities
  1. The Fundamentals of Six Sigma
    • Defining a Process
    • VOC & CTQ’s
    • Cost of Poor Quality (COPQ)
    • Pareto Analysis (80:20 rule)
  1. Lean Six Sigma Projects
  • Six Sigma Metrics
  • Business Case & Charter
  • Project Team Selection
  1. 1.4 Lean Fundamentals
  • Lean & Six Sigma
  • History of Lean
  • The Seven Deadly Muda
  • Five-S (5S)
  • Different Mapping Methods
  1. DEFINE TOLLGATE

 

MEASURE STAGE (DAY 2-4)

    1. Process Definition
  • Cause & Effect Diagrams
  • Process Mapping Methods/ Value Stream Mapping
  • X-Y Diagram
  • FMEA: Failure Modes & Effects Analysis
    1. Six Sigma Statistics
  • Basic Statistics
  • Descriptive Statistics
  • Distributions & Normality
  • Graphical Analysis
    1. Measurement System Analysis
  • Precision & Accuracy
  • Bias, Linearity & Stability
  • Gage R&R
  • Variable & Attribute MSA
    1. Process Capability
  • Capability Analysis
  • Concept of Stability
  • Attribute & Discrete Capability
  • Monitoring Techniques
    1. MEASURE TOLLGATE
    2. DMADV and DFSS Applications

 

ANALYZE STAGE (DAY 5-7)

  1. Patterns of Variation
  • Multi-Vari Analysis
  • Classes of Distributions
  1. Inferential Statistics
  • Understanding Inference
  • Sampling Techniques & Uses
  • Sample Size
  • Central Limit Theorem
  1. Hypothesis Testing
  • Goals of Hypothesis Testing
  • Statistical Significance
  • Risk; Alpha & Beta
  • Types of Hypothesis Test
  1. Hypothesis Testing: Normal Data
  • 1 & 2 sample t-tests
  • 1 sample variance
  • One Way ANOVA
  1. Hypothesis Testing: Non-Normal Data
  • Mann-Whitney & Mood’s Median
  • Kruskal-Wallis
  • Moods Median
  • Friedman
  • Sample Sign
  • Sample Wilcoxon
  • 1 and 2 Sample Proportion
  • Chi-Squared (Contingency Tables)
  • Test of Equal Variances
  1. Lean Tools at Analyze Stage
  • Theory of Constraints
  • The Penny Factory
  • Value Stream Mapping
  • Mapping Questions
  1. ANALYZE TOLLGATE
  2. DMADV and DFSS Applications

 

IMPROVE STAGE (DAY 8-10)

  1. Simple Linear Regression
  • Correlation
  • Regression Equations
  • Residuals Analysis
  1. Multiple Regression Analysis
  • Non-Linear Regression
  • Multiple Linear Regression
  • Confidence Intervals
  • Residuals Analysis
  • Data Transformation, Box Cox
  • Stepwise Regression
  • Logistic Regression
  1. Designed Experiments
  • Experiment Objectives
  • Experimental Methods
  • DOE Design Considerations
  1. Full Factorial Experiments
  • 2k Full Factorial Designs
  • Linear & Quadratic Models
  • Balanced & Orthogonal Designs
  • Fit, Model & Center Points
  1. Fractional Factorial Experiments
  • Designs
  • Confounding Effects
  • Experimental Resolution
  1. TRIZ INNOVATION
  • TRIZ Fundamentals
  • 40 Principles of TRIZ
  • Application of TRIZ
  1. DESIGN THINKING CONCEPTS
  2. IMPROVE TOLLGATE

 

CONTROL STAGE (DAY 11-12)

  1. Lean Controls
  • Control Methods for 5S
  • Kanban
  • Poka-Yoke (Mistake Proofing)
  1. Statistical Process Control (SPC)
  • Data Collection for SPC 5.2.2 I-MR Chart
  • Xbar-R Chart
  • U Chart
  • P Chart
  • NP Chart
  • X-S chart
  • CumSum Chart
  • EWMA Chart
  • Control Methods
  • Control Chart Anatomy
  • Subgroups, Variation, Sampling
  • Center Line & Control Limits
  1. Six Sigma Control Plans
  • Cost Benefit Analysis
  • Elements of the Control Plan
  • Elements of the Response Plan
  1. CONTROL TOLLGATE

 

SIX SIGMA DEPLOYMENT (DAY 12)

  1. Stages of Deployment
  • Assess-Launch-Planning
  • Implementation
  • Institutionalization
  • Sustaining
  1. Six Sigma Organization and Roles
  2. Pitfalls to Avoid
  3. Peoples, Process, Policy
  4. VISION of Six Sigma
  5. DEPLOYMENT TOLLGATE

 

Program Inclusions:

 

  • DURATION: 12 day staggered seminar-workshop
  • Pre-REQUISITE: Certified Green Belt
  • INCLUSION: Hard copy of courseware
  • CERTIFICATION: Six Sigma Experts (Arizona, USA) www.6sigmaexperts.com
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