Lean Six Sigma Black Belt Training and Certification

Day 1: Introduction and Define Phase

1. Welcome and Introduction

• Course Objectives and Structure

• Role of a Black Belt in Lean Six Sigma Projects

• Overview of Lean Six Sigma Methodology

1. Lean Six Sigma Fundamentals

• History and Evolution of Lean and Six Sigma

• Key Concepts: Value, Waste, and Variability

• Lean vs. Six Sigma: Synergy and Differences

1. Understanding the Customer

• Voice of the Customer (VoC)

• Critical to Quality (CTQ) Requirements

• Kano Model and Customer Journey Mapping

1. Define Phase

• Project Selection and Scoping

• Developing a Project Charter

• SIPOC Diagram (Suppliers, Inputs, Process, Outputs, Customers)

• High-Level Process Mapping

• Stakeholder Analysis and Management

1. Case Study Introduction

• Overview of the Case Study

• Initial Project Definition and Chartering

1. Wrap-Up and Q&A

• Summary of Key Concepts

• Questions and Discussion

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Day 2: Measure Phase

1. Review of Day 1

• Key Takeaways and Lessons Learned

• Addressing Questions

1. Measure Phase Overview

• Importance of Measurement in Lean Six Sigma

• Defining Metrics and Key Performance Indicators (KPIs)

1. Data Collection and Measurement Systems

• Data Collection Planning and Techniques

• Types of Data and Measurement Scales

• Measurement System Analysis (MSA)

• Introduction to Gage R&R

1. Process Mapping and Analysis

• Detailed Process Mapping Techniques

• Value Stream Mapping (VSM)

• Identifying Process Bottlenecks and Waste

1. Process Capability

• Introduction to Process Capability Analysis

• Calculating Cp, Cpk, and Ppk

• Understanding Process Variability

1. Case Study Application

• Applying Measurement Tools to the Case Study

• Data Collection and Analysis Exercise

1. Wrap-Up and Q&A

• Summary of Key Concepts

• Questions and Discussion

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Day 3: Analyze Phase

1. Review of Day 2

• Key Takeaways and Lessons Learned

• Addressing Questions

1. Analyze Phase Overview

• Root Cause Analysis Techniques

• Fishbone Diagram (Ishikawa) and 5 Whys

• Pareto Analysis

• Introduction to Hypothesis Testing

1. Advanced Data Analysis Techniques

• Descriptive Statistics

• Correlation and Regression Analysis

• Introduction to Design of Experiments (DOE)

1. Failure Modes and Effects Analysis (FMEA)

• FMEA Process and Implementation

• Identifying and Prioritizing Failure Modes

1. Case Study Application

• Analyzing Data and Identifying Root Causes

• Developing Hypotheses and Testing

1. Wrap-Up and Q&A

• Summary of Key Concepts

• Questions and Discussion

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Day 4: Improve Phase

1. Review of Day 3

• Key Takeaways and Lessons Learned

• Addressing Questions

1. Improve Phase Overview

• Brainstorming Techniques for Solution Generation

• Prioritization Methods (Impact-Effort Matrix, Pugh Matrix)

• Solution Development and Selection

• Pilot Testing and Implementation Planning

1. Lean Tools for Improvement

• 5S Methodology

• Kaizen and Continuous Improvement

• Error Proofing (Poka-Yoke)

• Kanban and Pull Systems

1. Design of Experiments (DOE)

• DOE Fundamentals

• Planning and Conducting Experiments

• Analyzing DOE Results

1. Case Study Application

• Developing and Implementing Improvement Solutions

• Conducting Pilot Tests and Analyzing Results

1. Wrap-Up and Q&A

• Summary of Key Concepts

• Questions and Discussion

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Day 5: Control Phase and Project Closure

1. Review of Day 4

• Key Takeaways and Lessons Learned

• Addressing Questions

1. Control Phase Overview

• Importance of Sustaining Improvements

• Developing Control Plans

• Statistical Process Control (SPC) Overview

1. Control Tools and Techniques

• Control Charts (e.g., X-bar, R-chart)

• Standard Operating Procedures (SOPs)

• Visual Management and Auditing

1. Project Closure and Documentation

• Finalizing Project Documentation

• Project Handoff and Transition Planning

• Lessons Learned and Knowledge Sharing

1. Case Study Presentation

• Presenting the Final Project and Outcomes

• Feedback and Discussion

1. Certification Process

• Review of LSSBB Certification Requirements

• Preparation for the Certification Exam

1. Final Q&A and Wrap-Up

• Summary of the Five-Day Training

• Next Steps in Lean Six Sigma Journey