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Lean Six Sigma Black Belt Course Content and Outline

Introduction to Lean Six Sigma:

	Introduction
	Higher Standards for Higher Performance
	Input Determines Output
	Lean Six Sigma Defined
	What's In a Name?
	Success Stories
	The Sigma Level
	The 99.9% Problem
	Calculating the Sigma Level - Toolset
	DNA of a Champion
	Lean Six Sigma Framework
	DMAIC - The Lean Six Sigma Improvement Process
	Lean and DMAIC
	Thought Process Mapping - Toolset
	Organizing for Success
	Working Relationships
	Critical Success Factors
	Exercises and Quiz

Define I - The Value Stream:

	Define - Introduction
	Process Thinking
	The Source of Value
	Value Stream Leverage
	Process Mapping - Overview
	Process Mapping (SIPOC) Toolset
	Process Flow Charts and Swim Lanes
	Value-Added Flow Charts
	Spaghetti Charts
	Value Stream Mapping Toolset
	Pareto Chart Toolset
	Balanced Scorecard Toolset
	Project Charter Toolset
	Project Tracking Toolset
	Stakeholder Analysis - RACI Matrix
	Exercises and Quiz

Define II - Voice of the Customer:

	Voice of The Customer
	Focus on The Customer
	Understanding Customer Requirements
	Where to Go For Customer Requirements
	Conducting Surveys
	More on Surveys
	Surveys - Sampling Frame
	Structuring Survey Questions
	The Degree of Uncertainty in Sampling
	Guideline for Margin of Error
	Affinity Diagram Toolset
	CTQC Tree Diagram Toolset
	Operational Definition Toolset
	Voice Of The Customer As Specifications
	QFD Toolset
	DEFINE - Progress Review
	Exercises and Quiz

Measure I - Measurements and Basic Statistics:

	Measurements and Basic Statistics
	Business Problem Solving
	Basic Statistical Terms
	Descriptive and Inferential Statistics
	Measurements
	Discrete vs. Continuous Measurements
	Measurement Subjects
	Graphical Summaries
	Histogram Toolset
	Measuring Central Tendency
	Quantifying Process Variability
	The Normal Distribution
	Exercises and Quiz

Measure II - Measurement System Analysis:

	Measurement System Analysis - Introduction
	Measurement As A Process
	Cause & Effect Matrix Toolset
	The Analysis of Measurement Systems
	The Requirements of Measurement Systems
	Gage R & R
	MSA - Graphing
	Attribute Measurement System Analysis
	Calibration of Measurement Systems
	Collecting Data
	Developing a Sampling Plan
	Baseline Performance
	Derivative Performance Metrics - Throughput Yield
	Derivative Performance Metrics - Rolled Throughput Yield
	The Sigma Level Revisited
	Exercises and Quiz

Measure III - Charting Process Behavior:

	Introduction - Charting Process Behavior
	Trend Chart Toolset
	SPC - Introduction and Background
	SPC - Introduction to Control Charts
	SPC - Control Chart Limits
	SPC - More On Control Limits
	Implementing SPC
	SPC Chart Selection
	Rational Subgrouping Toolset
	X and Moving Range Charts - Toolset
	Attribute Control Chart Toolset
	X-bar and R Chart Toolset
	Process Capability Toolset
	MEASURE - Progress Review
	Exercises and Quiz

Analyze I - Potential Root Causes:

	ANALYZE I - Introduction
	Finding The Root Cause
	Cause & Effect Diagram Toolset
	Alternative To The Cause & Effect Diagram
	5-Why, 1-How
	A Combination of 5-Why, Pareto, and Trend Charts
	Box Plots Toolset
	Scatter Plot Toolset
	Correlation and Regression Analysis
	Multiple Regression Toolset
	Logistic Regression Toolset
	Factors In Determining Sample Size
	Estimating Population Mean
	Exercises and Quiz

Analyze II - Hypothesis Testing:

	ANALYZE II - Introduction
	Introduction to Hypothesis Testing
	The Process On Trial
	The Hypothesis - Accept or Reject?
	Types of Error
	Power Analysis
	Power Analysis - Factors
	Hypothesis Testing
	Confidence Intervals
	Treatment Comparisons - Control Charts
	Comparing One Proportion to a Standard
	Comparing Two Proportions - Z-test Toolset
	Comparing Multiple Proportions - Chi-Square
	Comparing One Mean to a Standard - t-test
	Comparing Two Means - t-test Toolset
	Comparing Multiple Means - ANOVA /F-test Toolset
	Confidence Intervals - Least Significant Difference
	Comparing One Variance to a Std. - Chi-Square
	Comparing Two Variances - F-test Toolset
	Parametric vs. Non Parametric Tests
	Non Parametric Toolset
	Hypothesis Testing Learning Lab
	Exercises and Quiz

Analyze III - Design of Experiments:

	Design of Experiments - Introduction
	Design of Experiments - History
	Design of Experiments - Components
	Design of Experiments - Principles
	Design of Experiments - Purpose
	Design of Experiments - Process
	Design of Experiments - Guidelines
	Selecting the Right Design
	Blocking
	Blocking and Tackling
	Faster Deliveries Through Experimentation
	Beyond One-Factor Experiments
	Two Level Full Factorial Toolset
	Two Level Fractional Factorial Toolset
	General Factorial Toolset
	DOE Power and Sample Size
	Designing An Experiment To Save The Kingdom
	Selling More Coffee with Design Experiments
	Better Pizza Through Design of Experiments
	Brewing Better Beer Using DOE
	Additional Subjects
	ANALYZE - Progress Review
	Design of Experiments Exercises and Quiz

Improve:

	Improve
	Design for Six Sigma (DFSS)
	Benchmarking
	Brainstorming
	Narrowing Down The List of Ideas
	FMEA Toolset
	Error-proofing
	Prioritizing and Selecting a Solution
	The A3 One-Page Report
	Continuous Flow Toolset
	Quick Changeover Toolset
	Cellular Processing Toolset
	The Theory of Constraints (TOC) Toolset
	Pull Scheduling
	Corrective Action Matrix
	Piloting a Solution
	System Dynamics
	Characteristics of Dynamic Systems
	System Dynamics Example
	Another System Dynamics Example
	System Dynamics Application
	System Dynamics Summary
	IMPROVE - Progress Review
	Exercises and Quiz

Control:

	Control
	Control Charts Revisited
	The Process Control Plan
	More On FMEA
	Visual Control
	5-S Approach
	CHECK Process
	Total Productive Maintenance
	TPM Objectives & Benefits
	TPM Metrics
	TPM Core Elements
	TPM Maintenance Activities
	Best Practices and Lessons Learned
	Standardized Work - Documenting Process Changes
	Ending the Project
	CONTROL - Progress Review
	Exercises and Quiz

Leading Teams And Leading Change:

	Leadership Introduction
	Fueling The Improvement Engine
	Leadership Characteristics
	Practice, Study and Reflection - Learning by Modeling
	Leading Teams
	Developing an Effective Team
	Improving Team Development
	Leading Change
	Leading Change - Continued
	Success Factors For Effective Change Management
	Exercises and Quiz
	Course Completion
	The Lean Six Sigma Journey

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