Lean Six Sigma Black Belt

EngineRoom

Course Map

Total Estimated Hours:  140

SESSION 1: Introduction To Lean Six Sigma 3.65 HOURS

  • A MoreSteam Welcome
  • Introduction to Lean Six Sigma
  • The Cost of Poor Quality
  • Input Determines Output
  • The 5 Lean Principles
  • The 8 Forms of Waste
  • History of Lean Six Sigma
  • The 99.9% Problem
  • DMAIC Improvement Process
  • Thought Process Mapping Toolset
  • Organizing for Success
  • Roles and Responsibilities
  • Critical Success Factors
  • Learning and Problem Solving with AI
  • Session Wrap-Up and Skill Check

SESSION 2: Define - Starting a Project and Leading Teams 8.9 HOURS

  • Introduction to the Define Phase
  • Balanced Scorecard Toolset
  • Project Selection Toolset
  • Writing Effective Problem Statements
  • Project Charter Toolset
  • Gantt Chart Toolset
  • Leadership Thinking
  • Robot Leadership
  • Fueling The Improvement Engine
  • Leading Teams
  • Leading Teams II
  • 4 Conversations Toolset
  • Change Management I: Leading Change
  • Change Management II: Change is a Process
  • Change Management III: Delivering Results
  • Leader Standard Work Toolset
  • RACI Matrix
  • Leadership Reflection
  • Session Wrap-Up and Skill Check

SESSION 3: Define - Voice of the Customer 7.55 HOURS

  • Introduction to Voice of the Customer
  • Understanding Customer Requirements
  • Where to Go For Customer Requirements
  • Surveys
  • The Degree of Uncertainty in Sampling
  • Calculating Margin of Error
  • Introduction to EngineRoom®
  • Affinity Diagram Toolset
  • CTQC Tree Diagram Toolset
  • Operational Definition Toolset
  • Voice Of The Customer As Specifications
  • Quality Function Deployment (QFD) Toolset
  • Session Wrap-Up and Skill Check

SESSION 4: Define - Mapping the Process 4.7 HOURS

  • Introduction to Process Mapping
  • Gemba Walks
  • Types of Process Maps
  • SIPOC Map Toolset
  • Process Flow Charts
  • Value-Added Flow Charts
  • Spaghetti Diagrams
  • Takt Time
  • Value Stream Mapping Toolset
  • Define Phase Progress Review
  • Session Wrap-Up and Skill Check
  • St. Sigma Case Study Define

SESSION 5: Measure - Measurements and Basic Statistics 7.6 HOURS

  • Introduction to the Measure Phase
  • Solving Problems with Statistics
  • Basic Statistical Terms
  • Descriptive and Inferential Statistics
  • Measurement and Data Types
  • Selecting the Best Measurement
  • Graphical Summaries
  • Graphical Summaries II
  • Pareto Chart Toolset
  • Histogram Toolset
  • Understanding Variation
  • Measuring Central Tendency
  • Quantifying Process Variability
  • Box Plots Toolset
  • The Normal Distribution
  • Distribution Identification
  • Data Cleansing
  • Session Wrap-Up and Skill Check

SESSION 6: Measure - Measurement System Analysis 7.55 HOURS

  • Introduction to Measurement as a Process
  • Cause & Effect Matrix Toolset
  • Introduction to Measurement Systems Analysis (MSA)
  • Measurement System Requirements
  • MSA for Continuous Data: Gauge R&R
  • MSA for Attribute Data
  • Calibration of Measurement Systems
  • Data Collection
  • Sampling Plan
  • Factors In Determining Sample Size
  • Session Wrap-Up and Skill Check

SESSION 7: Measure - Charting Process Behavior 11.35 HOURS

  • Introduction to Statistical Process Control
  • Trend Chart Toolset
  • Introduction to Control Charts
  • Control Chart Limits
  • XmR Charts Toolset
  • Run Tests
  • Rational Subgrouping
  • X-bar and R Charts Toolset
  • Attribute Control Charts Toolset
  • Deming's Funnel Experiment
  • Stratifying with Stage Variables
  • Control Chart Simulation: Chart Noir
  • Measuring Capability
  • Throughput Yield and Rolled Throughput Yield
  • Calculating DPMO and Sigma Level
  • Process Capability Toolset
  • Data Transformation
  • Containment
  • Measure Phase Progress Review
  • Session Wrap-Up and Skill Check
  • St. Sigma Case Study Measure

SESSION 8: Analyze - Identifying Potential Root Causes 10.4 HOURS

  • Introduction to the Analyze Phase
  • The Path to Root Cause
  • Root Cause Analysis Framework
  • Cause and Effect Diagram Toolset
  • 5-Why, 1-How Analysis
  • Root Cause Tree Analysis Toolset
  • Root Cause Stratification Toolset
  • FMEA Toolset
  • Scatter Plot Toolset
  • Simple Regression Analysis
  • Multiple Regression Analysis Toolset
  • Binary Logistic Regression Toolset
  • Session Wrap-Up and Skill Check

SESSION 9: Analyze - Hypothesis Testing Fundamentals 5.1 HOURS

  • Introduction to Hypothesis Testing
  • The Null and Alternative Hypotheses
  • The Significance Level
  • The Significance Level & Types of Error
  • Choosing a Hypothesis Test
  • Interpreting Results With p-Values
  • One-Tailed and Two-Tailed Tests
  • Power Analysis
  • Session Wrap-Up and Skill Check

SESSION 10: Analyze - Mastering Hypothesis Testing 12 HOURS

  • Mastering Hypothesis Tests
  • One Mean t-Test
  • Two Means t-Test
  • Multiple Means Test (ANOVA)
  • One Proportion Test
  • Two Proportions Test
  • Multiple Proportions Test
  • One Variance Test
  • Two Variances Test
  • Parametric vs. Non Parametric Tests
  • Non Parametric Toolset
  • Hypothesis Test Simulation: HyCourt TV
  • Session Wrap-Up and Skill Check

SESSION 11: Analyze - Design of Experiments Fundamentals 5.75 HOURS

  • Design of Experiments (DOE) Introduction
  • DOE History
  • DOE Components
  • DOE Principles
  • DOE Purpose
  • DOE Process
  • DOE Guidelines
  • Selecting the Right Design
  • Blocking Variables I
  • Blocking Variables II
  • DOE Simulation: Faster Deliveries
  • Session Wrap-Up and Skill Check

SESSION 12: Analyze - Mastering Experimental Designs 25.4 HOURS

  • Mastering Experimental Designs
  • Two Level Full Factorial Toolset
  • Two Level Fractional Factorial Toolset
  • General Factorial Toolset
  • Design of Experiments - Power & Sample Size
  • DOE Simulation: Save The Kingdom
  • DOE Simulation: Better Pizza
  • DOE Simulation: SigmaBrew Coffee
  • Taguchi Methods
  • Analyze Phase Progress Review
  • Session Wrap-Up and Skill Check
  • St. Sigma Case Study Analyze

SESSION 13: Improve 12.45 HOURS

  • Introduction to the Improve Phase
  • Design for Six Sigma
  • Benchmarking
  • Brainstorming
  • Structured Brainstorming
  • Multi-Voting
  • Error-proofing
  • Continuous Flow Toolset
  • Line Balancing (Heijunka)
  • The Theory of Constraints (TOC) Toolset
  • Quick Changeover Toolset
  • Cellular Processing Toolset
  • Introduction to Pull Systems
  • Types of Pull Systems
  • Core Process Pull Systems (WIP Cap) Toolset
  • Replenishment Pull Systems Toolset
  • System Dynamics Toolset
  • Prioritizing and Selecting a Solution
  • Corrective Action Matrix
  • Piloting a Solution
  • Kaizen Toolset
  • The A3 One-Page Report
  • Improve Phase Progress Review
  • Session Wrap-Up and Skill Check
  • St. Sigma Case Study Improve

SESSION 14: Control 6.2 HOURS

  • Introduction to the Control Phase
  • Control Charts Revisited
  • Process Control Plan
  • Prioritizing Changes with FMEA
  • Visual Management
  • 5-S Approach
  • CHECK Process
  • Introduction to Total Productive Maintenance (TPM)
  • TPM Objectives and Benefits
  • TPM Metrics
  • Best Practices
  • Standard Work
  • Project Close-Out
  • Control Phase Progress Review
  • Session Wrap-Up and Skill Check
  • St. Sigma Case Study Control
  • Course Completion and Feedback
  • The Lean Six Sigma Journey