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SIX SIGMA MANUFACTURING BLACK BELT

 

Commences January 8th 2013 (Leamington Spa)

3500+VAT per delegate

inclusive of:

  • Comprehensive training manual

  • Lunches and refreshments

  • Lean Sigma Toolkit

  • Access to Lean Sigma Website

4book places

     

INTRODUCTION

As an expert process improvement resource, Black Belts are tasked with delivering measurable benefits through quantifiable improvement projects. This 18-day programme will develop Black Belts who are skilled in leading, executing and completing projects. They will be trained as experts in Six Sigma tools and concepts, and develop their ability to demonstrate appropriate leadership, creativity and communication skills. This training is designed with a modular format which combines training inputs and practical simulation activities with an ongoing focus on project progress and reviews.

Objectives:

  • Ensure the DMAIC flow and application of tools are fully understood

  • Introduce the leadership and change management skills to support the Black Belt role

  • Provide practitioner training in the more complex statistical tools required within the Black Belt toolkit

  • Provide guidance on project delivery

ACCREDITATION

The Smallpeice accreditation process for Six Sigma Black Belts incorporates completing a project for formal assessment and passing a multi-choice examination.

BQF Accreditation Option: Smallpeice courses are also licensed for BQF (British Quality Foundation) accreditation, enabling candidates to achieve this external accreditation benchmark. The accreditation steps are as described above, with an additional 250 fee to cover the licensed accreditation route (Note: more details on accreditation options will be provided in Block 1).

 

BLOCK 1

Defining the
Problem

Understanding the
Current State &
 Introduction to Statistics

Data Collection Planning &
 Measurement
Systems Analysis

Leading
Effective Change

January 8

January 9

January 10

January 11

Programme Introduction

  • Programme Objectives & Certification Routes

  • Improvement Project Roles and Responsibilities

 

Improvement Roadmap

  • Introduction to the DMAIC roadmap

  • Pre-requisites for successful projects

  • Project selection criteria

  • Application of the DMAIC toolkit in daily work

 

The Define Phase

  • Writing problem statements

  • Setting the project objectives

  • Scoping the project the concept of y =f (x)

  • Mapping the high level process SIPOC mapping tool

  • Linking the problem to the voice of the customer

  • Defining critical to quality characteristics

  • Drawing up the project charter

 

Understanding the Current State

  • Introduction to the Measure Phase

  • Detail Process flow charting techniques

  • Taking a proactive approach to identifying weaknesses in the current process

  • Use of failure mode effects analysis (FMEA) to identify potential opportunities for defects

  • Evaluating, reducing & managing risk

 

Introduction to Statistical Concepts & Minitab

  • Introduction to basic statistics and their context in Lean Sigma projects

  • Learning to describe data -measures of location, variation and shape

  • Communicating statistics to a non-technical audience

  • Introduction to Minitab software

 

Data Collection Planning

  • Understanding different types of process variation

  • Selecting what to measure

  • Key considerations for data collection planning

  • Deciding how to collect the data: an introduction to sampling techniques

  • Completing a data collection plan

  • Writing effective operational definitions for data collection

 

Measurement Systems Analysis

  • Checking the measurement system

  • Understanding measurement system variation

  • An introduction to Gauge Repeatability and Reproducibility

  • Gauge R & R in Minitab

 

Preparing and Planning for Change

  • Understanding the nature of change

  • Analysing enablers and barriers to change

  • Analysing and managing stakeholders

  • Understanding the role of the project sponsors

  • Writing an effective communication plan

Leading Process Change

  • Barriers & enablers to team effectiveness

  • Influencing for change

 

Facilitating Improvement Activities with Teams

  • Identifying activities

  • Organising your team & stakeholders

  • Facilitation Skills

 

Contracting for Success

  • Review next steps

  • Action Planning

 

 

BLOCK 2

Analysing Performance & Verifying Root Causes

Optimising the Process

Designing the
Future State & Sustaining
the Improvements

March 5

March 6

March 7

March 8

Taking a Structured Approach to the Analyse Phase

  • Introduction to the analyse phase

  • 5 Why Approach to problem solving

  • Forming and testing hypotheses

  • Writing an analysis plan

 

Visualising the Data

  • What shape is your data? Histograms

  • Visualising Descriptive Statistics Graphical Summary Tool

  • Understanding confidence limits

 

Assessing Process Control

  • What is happening over time? Time Series Plots

  • Understanding process control

  • Anatomy & use of Control charts

  • Applications of SPC Charts

 

Assessing Process Capability

  • Understanding process capability

  • Calculating process capability for Continuous and Attribute Data

  • Selecting appropriate capability metrics & indices

  • Dealing with non-normal data

 

Verifying the Root Cause

  • Link to cause and effect diagram

  • Stratifying the data use of box plots

  • Are there any relationships? - Scatter Diagrams

  • Where are the biggest opportunities? - Pareto

  • Links to project storyboard hints and tips for summarising and presenting the analysis

  • Introduction to significance testing approach

 

Introduction to Regression Analysis

  • Understanding correlation

  • Introduction to simple linear regression

  • Application in Lean Sigma Projects

 

Optimisation Processes:
Design Of Experiments

  • Introduction to designed experiments (DOE)

  • Applications of DOE techniques

  • Basic system optimisation

  • Screening techniques using DOE

  • Optimising a worked example

Improve Phase: Solution Generation & Piloting

  • Challenges of the Improve Phase

  • Generating alternative solutions

  • Evaluating and selecting the best solution

  • Piloting & solution introduction

 

Solution Introduction  & Control 

  • Developing a control plan

  • Prevention & detection systems

  • Choice of control method

  • Out of control action planning

  • Handover & transferring benefits

  • Planning for continuous improvement

 

Contracting for Success

  • Project reviews, lessons learnt & next steps

 

 

BLOCK 3

Define Phase Revisited

Advanced Data Collection Planning

Advanced Statistics

Hypothesis Testing

Regression Analysis

April 8

April 9

April 10

April 11

April 12

Course Introduction

  • Expectations & objectives

  • The role of a Black Belt

  • Black Belt project selection

 

Define Phase Revisited

  • Scoping complex cross-functional projects

  • Use of quality function deployment to understand the voice of the customer

  • Benefits calculation & tracking

  • Planning for change

  • Managing your Black Belt Project

 

Advanced Data Collection Planning

  • Planning data collection for Black Belt projects

  • Sampling techniques re-visited

  • Gauge R&R for variable and attribute data (bias & linearity)

  • Statistical process control for attribute and variable data

  • Process capability revisited

 

Advanced Statistics

  • Basic statistics and probability revisited

  • Probability distributions

  • The central limit theorem

  • Dealing with non-normal data

  • Planning and communicating data analysis

Hypothesis Testing

  • Use of inferential statistics

  • Significance testing route map

  • Analysis of variable and attribute data

  • Power & sample size

  • Non-parametric techniques

 

Multi-Variable Regression

  • Introduction to multiple regression

  • Analysis of multi-variable data

  • Further diagnostic techniques

  • Signpost to advanced regression techniques

 

 

BLOCK 4

Design of Experiments

Control Phase

May 13

May 14

May 15

May 16

May 17

Design of Experiments

  • Introduction to designed experiments (DOE)

  • Applications of DOE techniques

  • Basic system optimisation

  • Screening techniques using DOE

  • Optimising a worked example

 

Advanced Design of Experiments

  • Review of Full Factorial Designs

  • Benefits & limitations of basic DOE techniques

  • Introduction to Fractional Factorial

  • Screening Designs

  • Overview of advanced techniques

Advanced Design of Experiments (Contd)

  • Taguchi techniques

  • Mixed & multi-level experiments

  • Response surface designs
    (CCD, CCF & Box-Behnken designs)

  • Introduction to evolutionary experimentation
    (EVOP techniques)

 

Note: All DOE modules Include SimWare Simulations & Minitab Analysis, as well as practical experimentation examples

 

 

Control

  • Control phase techniques

  • Embedding the change within the business

  • Application of long term MSA

  • Long-term control

 

Intro to DFSS

  • Introduction to design for six sigma and the DMADV methodology

  • Links to DMAIC

 

Review & Next Steps Planning

 

 

Commences January 8th 2013 (Leamington Spa)

3500+VAT per delegate

inclusive of:

  • Comprehensive training manual

  • Lunches and refreshments

  • Lean Sigma Toolkit

  • Access to Lean Sigma Website

4book places

     

Smallpeice Enterprises Limited 2012