Lean Six Sigma Black Belt
Description: Lean Six Sigma is a methodology that maximizes shareholder value by achieving the fastest rate of improvement in customer satisfaction, cost, quality, process speed and invested capital. Reducing variation & lead time.
Duration: 160 hours
This program is the standard 4-week training spread over several months. Between weeks the student will go back to the company and apply the new skills they have learned.
| Overview |
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* Six Sigma's General Scope * DMAIC Methodology * Six Sigma's Financial Benefits * The impact of Six Sigma in the Organization * Six Sigma's Language |
| Definition |
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* Project's Planning * Projet's Definition * Projet's Selection * Development of a business case * Team building * Defining rolls and responsabilities (team work) * Customer's voice supporting the project * Costs of Poor Quality (COPQ) * Translating Customers Needs within Specific Requirements (CTQs) * SIPOC Chart * Lean Manufacturing History * 5'S * 8 Wastes (Mudas) * SMED (Single Minute Exchange) * Process Mapping (As-Is proces) * Definition phase review |
| Measurement |
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* Data's attributes * Descriptive and Inferential Statistical * Metrics Definition * Measurement System Analysis * Repetibility and Reproducibility * Techniques of obtaining data * Calculating sample size * Plan of obtaining data *Undestanding the variation * Statistical thought and control charts * Process capability measurement * Calculating Process's Six Sigma Level * Rolled Throughput Yield * Unfolded visual of he line execution of bases of the project * Statistical Software Training * Performance Metrics * Visual Control * Ergonomics and Security enviroment * Failure Mode and Effect Analysis (FMEA) * Measurement phase review |
| Analysis |
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* Visual Interface (Histogram, Tendency, Pareto, Scatter charts) * Process Mapping detailed (Low Level) Critics Areas * Analysis of Added Value * Cause-Effect Analysis (a.k.a. Fishbone, Ishikawa) * Affinity Diagram * Data's Segmentation & Stratification * Correlation & Regression (lineal & multiple) * Process Development (Cp, Cpk, Pp, Ppk) * Process capability short term vs long term * Hipothesis testing * Variation Analysis (ANOVA), 2 samples T-Test, Chi Squared Test * Experiments (DOE) - Full, Fractional Factorials, Design * Verification of Root-Causes * Determining opportunities for improvement (defects vs finances) * Review the Project * Industrial Engineering Highlights * Process Lay-Out * Cycle Time study * Balance and schedule work * Kanban * Kaizen * Analysis Phase Review |
| Improvement |
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* Brainstorm * Multi-Voting * Response Surface (DOE Optimization) * DOE Characterization * Process Simulation * Unfolded of the quality function (Quality House QFD) * Identifying a solution * POKA YOKE (Mistake Proofing Your New Process) * Pilot Test of the solution * Planning the implementation * Statistical Software Training * Planning the culture's change in the Organization * Theory of Constrains * Value Stream Mapping * Celular Manufaturing * 8D * Improvement Phase review |
| Control |
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* Improvement Process Assurance * Statistical Process Control (SPC) * Rational Sub-group * Process inputs and outputs standardization * Developing a Process Control Plan * Documenting the Process * Systemic Thought * Improvements Validation in Quality terms * Improvements Validation in Financial terms * Process Mapping Before and After * Training in Statistical Software * Control Phase review |