1.1.4 - BLACK BELT UPGRADE

Objectives:

This training comes as a complement for that ones who already have formation in the DMAIC methodology (Define, Measure, Analyze, Improve and Control) as Green Belts. Its focus is to teach the basis, concepts and tools of the Lean Six Sigma at Black Belt level, qualifying the practitioner for the development of strategic projects and of higher complexity.

In short:

• To associate and execute the Lean Methodology.
• Why and when to use the Lean Six Sigma model.
• To create a shared need in the organization for the implementation of the Six Sigma Methodology
• To comprehend the tools that support the methodology.
• To develop Leadership competencies for the introduction and management of changes in the organization.
• To improve the knowledge in statistical techniques.
• To exercise the Black Belt role as coach for Lean Six Sigma projects

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:

• Certificated Green Belts or in late stages for certification
• Basic knowledge of mathematics and statistics helps the practitioner in the better comprehension of the theme, still they are not impeditive

Course Duration:

• 80 hours. In general, the training occurs in two 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

Define

• Introduction to the Define Phase
• Indentifying Projects
• Financial impact of the projects and relation with the EVA (Economic Value Added)
• Metrics deployment – QFD – Quality Function Deployment
• Value Chain 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
• Qualitative tools review (process map, fishbone, cause & effect matrix and effort X impact matrix)
• Up time / Down time / Takt Time
• Data Type (Continuous and Discrete)
• Normal and Non-normal Data
• Measurement System Analysis (MSA) – Continuous and Discrete Data
• Data Collection Plan
• OEE (Overall Equipment Efficiency)
• FTT (First Time Through) / RTY (Rolled Throughput Yield) – Process yield Indexes
• Capability Analysis – Continuous Data (for normal and non-normal distributions)
• Capability Analysis – Discrete Data

Analyze

• FTA (Fault Tree Analisys) / FMEA
• Assessment

WEEK 2

Analyze

• Statistical Analysis Map
• Confidence Interval
• Sample Size
• Hypothesis Test (Comparison among  means, medians and variation using: Mood´s Median Test, Paired-Test, Levene Test)
• Logistic Regression
• Chi-Square,1-Proportion, 2-Proportion Tests
• Simple / Multiple Regression Analysis

Improve

• Introduction to the Improve Phase
• Review of DOE concepts
• Response Surfaces
• Monte Carlo Simulation
• Kaizen event
• Change Management

Control

• Introduction to Control Phase
• Control Process System and Control Plan (BPMS)
• Process Standardization
• Statistical Process Control (SPC) review for Continuous Data
• Statistical Process Control (SPC) review 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

• In Company – Carried out in Closed Classes, by customer request

Requirements for Certification:

• These training are only provided in company”. Thus, the certification depends on the customer requirements. In general, the followed standard is:
  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.

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

Specific Needs for Training Attendance:

• Computers – should be one for each three attendants (in company)
• Use of Minitab statistical software (in company)