Black Belt Course Content

• Introduction and Admin – SPACER
• Introduction to Lean Six Sigma - history, terminology, explanations
• Exercises on 7 Wastes and Calculating Sigma
• Structure and roles in Lean Six Sigma
• Overview of the stages of Lean Six Sigma - DMAIC
• Certification and project set up
• Gate review process
• DFSS overview

Define Phase

• Define phase overview
• Project Charters explained
• Sigma Logic
• Problem statements followed by exercise
• In / Out of Scope followed by exercise
• SMART goals followed by exercise
• SIPOC followed by exercise
• Team Creation, RACI and communications planning followed by exercise
• Voice of the customer / CTQ’s followed by exercise
• QFD
• Stakeholder analysis
• Project Planning,
• Risk Assessment and FMEA with exercise
• Project Launch, Project Folder followed by exercise

Measure Phase – Minitab used throughout

• Types of data
• Basic stats
• Central Tendency
• Variation and Tampering
• Graphical displays – Histograms, dot plots, box plots etc
• Introduction to Minitab
• Measure phase overview
• Process Mapping
• Value Stream mapping
• Data collection planning
• Measurement systems analysis and Gauge R&R
• Sampling 
• Process capability
• Control charts
• Moments of truth
• Theory of constraints
• Summary of Measure

Analyse Phase – Minitab used throughout

• Analyse phase overview
• Brainstorming
• Cause and Effect diagrams
• Data analysis – Pareto charts, run charts, frequency charts etc
• Confidence intervals
• Distributions
• Hypothesis testing
• T tests
• F tests
• ANOVA
• Chi squared
• Design of Experiments
• Regression and correlation
• Summary of analyse phase

Improve Phase

• Cup game to practice DMA phases
• Improve Phase overview
• Generating solutions and creativity
• 5S and visual management
• Little’s law
• Takt time
• Kanban and Flow (Push v Pull)
• TPM & OEE
• SMED
• Poka Yoka
• Kaizen
• Reducing complexity
• Standardisation
• Evaluating and selection solutions – Decision matrix etc
• Pilot testing
• Identifying solutions
• Cup game to practice Improve phase

Control Phase and course wrap up

• Control Phase overview
• Control plans
• Saving calculation – Cost of non quality  
• Project close out / handovers
• DMAIC summary
• Exam
• Wrap up

Effective Black Belt skills

• Presentation skills
• Facilitation skills
• Listening skills
• Questioning skills
• Lift Speeches
• Presenting your findings
• Team working including Belbin and exercise
• Running Kaizen events
• Running simulation exercises
• NLP
• Body Language
• Feedback and coaching
• Change management business
• Change management people
• Motivation skills
• Influencing skills
• Time management skills
• Basic Problem solving tools
• Affinity diagrams
• Decision trees
• Brainstorming / Negative brainstorming
• Force field analysis
• Voting

 

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