1.1.3 - LEAN SIX SIGMA BLACK BELT

Objectives:

The course has as central point, to teach the DMAIC Lean Six Sigma methodology for the BB, in a manner that the one utilizes it to generate the necessary changes in the organization. The approach is by means of practical and focused use of the methodology, associating the tools of the teamwork and analytical (statistic), aiming the BB to have success in the generation of changes over the process.  Besides the tools of DMAIC and the Lean Philosophy, the competencies and abilities for the BB to identify projects that are aligned with the strategic view of the business, the use of a financial language adequate to the process and the mentoring process together with other project leaders (GB´s and YB´s) are also emphasized.

In short:

• To link and execute the Lean Six Sigma methodology
• When and why to use the Lean Six Sigma model.
• To use the Lean Six Sigma methodology to get expressive results in the existing processes, products or services improvement.
• To comprehend the tools that support the methodology.
• Lean Six Sigma X Financial impact in the organizations.
• To develop leadership competencies for the introduction and management of changes in the organization.
• To create a Business Efficient Management culture in the company, generating a perception of increment of market value for the shareholders.
• To act as a facilitator within the areas of the organization.

Target Audience:

• Professionals from diverse working areas looking for development in the management area, in special, in the development of projects of processes improvement with the use of data analysis and teamwork.

Pre requirements:

• There are not any impeditive pre requirements for training attendance. It is suggested that the participants have the profile to leader project teams and that they are motivated by the challenge of promoting changes in the organization.
• Basic skills in mathematic and statistic help the participant in the better comprehension of the theme, still they are not impeditive.

Course Duration:

• 160 hours. In general, the training occurs in four separated weeks (one per month) in a manner that the BB develops his projects together with his training.

Programmatic Content:

WEEK 1

Introduction

• Six Sigma definition
• Six Sigma review
• DMAIC flux
• Process view
• Introduction to the Lean
• Lean principles
• The eight wastes of the Lean
• The association of Lean with Six Sigma – why does it bring advantages for us?
• Lean Six Sigma structure

Definition

• Introduction to Definition Phase
• Identifying Projects
• Financial impact of the projects and relation with the EVA (Economic Value Added)
• Management Models
• Metrics deployment – QFD – Quality Function Deployment
• Value Stream Map
• Identification of the customer needs – voice of the customer/ voice of the process
• Defining project metrics
• Scope definition – Matrix: it is and it is not / SIPOC
• Project charter

Measure

• Introduction to Measure Phase
• Process Map
• Up time / Down time / Takt Time
• Cause & Effect Diagram (Fishbone)
• Cause & Effect Matrix
• Impact X Effort Matrix
• Data Type (Continuous and Discrete)
• Basic Statistics – position measurements, dispersion measurements, statistical curves
• Normal and Non-normal Data
• Measurement System Analysis (MSA) – Continuous and Discrete Data
• Data Collection Plan
• Graphical Analysis – Pareto / Box Plot / Dispersion Diagram / Trend
• OEE (Overall Equipment Efficiency)
• FTT (First Time Through) / RTY (Rolled Throughput Yield) – Process yield Indexes
• Assessment

WEEK 2

Measure

• Capability Analysis – Continuous Data (for normal and non-normal distributions)
• Capability Analysis – Discrete Data

Analyze

• Introduction to Analyze Phase
• FMEA (Failure Mode and Effect Analysis) / FTA (Fault Tree Analysis)
• Equalization of Production
• One Piece Flow
• Rationalized Fluxes
• Bottom-neck Analysis
• Statistical Analysis Map
• Confidence Interval
• Sample Size
• Hypothesis Test (Comparison among  means, medians and variation using: ANOVA, Mood´s Median Test, 1-Sample-T, Paired-Test, 2-Sample-T, F-Test, Levene Test)
• Logistic Regression
• Chi-Square Test,1-Proportion Test, 2-Proportion Test
• Project Reviews and in-Class Presentation
• Assessment

WEEK 3

Analyze

• Simple / Multiple Regression Analysis

Improve

• Introduction to Improve Phase
• DOE (Design of Experiments) – Full Factorial
• Transfer Function
• Response Surface
• Monte Carlo Simulation
• Action Plans Generation – 5W2H
• Kaizen event
• Change Management
• Fast Set Up
• 5S
• Standard Operation
• Physical Places With Rationalized Fluxes
• Operation Cells
• Man-Work Flexibility
• Project Reviews and in-Class Presentation
• Assessment

WEEK 4

Control

• Introduction to Control Phase
• Control Process System and Control Plan (BPMS)
• Mistake Proofing Devices
• Process Standardization
• Statistical Process Control (SPC) for Continuous Data
• Statistical Process Control (SPC) for Discrete Data
• Execution related topics – How to become a good doer?
• Change Management
• Facilitation Techniques
• Simulation Exercise – Lean Six Sigma
• Project Reviews and in-Class Presentation
• Assessment

Training Modalities

• Open Courses – Multi-companies
• In Company – Carried out in Closed Classes, by customer request

Requirements for Certification

• Requirements for practitioners attending the open course
  1 – Development of one project with impact in the organization
  2 – At least 80% of frequency in the training.
  3 – At least 70% of success in the activities carried out during the training.
• This Training is also provided in-company. Thus, the certification depends of the customer requirements. In general, the standard to be followed is similar to the above described.

OBS: All participants earn the conclusion certificate if comply with 80% of frequency in the training.

Specific Needs for Training Attendance

• None (Multi-company training)
• Computers – should be one for each three attendants (in company)
• Use of Minitab statistical software (in company)