Black Belt is a further eight-day course for Lean Six Sigma certification. It’s designed to turn out skilled problem solvers and process improvers, who can also mentor and coach other team members. The result: completed projects and continuous improvement.
Candidates looking for advanced lean six sigma training to potentially become full time process improvement leaders or specialist trainers and coaches in continuous improvement.
Course pre-requisites Fully Certified or near fully certified Green Belt with a minimum of two completed improvement projects. Candidates need to have demonstrated an understanding of continuous improvement and have applied the PDCA and DMAIC roadmaps and toolkits practically. There is an expectation at Black Belt level that candidates have the potential to become competent workshop facilitators and trainers.
Day 1 – Change Management techniques – Employee engagement and empowerment Forming a team, Change Management for improvement projects using an easy to use roadmap and toolkit, Change acceptance tools and Mentoring Green Belts
Day 2 – Plan Do Check Act, Kaizen and Workshop Facilitation – PDCA cycle Kaizen thinking, roadmaps and accelerating projects. Kaizen workshop preparation, planning, event facilitation, newspaper and deliverables
Day 3 – DMAIC analytical tools Part 1 – Process metrics Measurement System Analysis for attribute and variable data Process capability Process stability and control charts
Day 4 – DMAIC analytical tools Part 2 – Correlation and Regression Hypothesis testing Quantitative analysis – means, variances and proportions Design of Experiments
Day 5 – Lean in the workshop Lean roadmaps – What does good look like? Lean workshop examples. Lean tools – Value Stream mapping, Process mapping, Visual Management, 5S, Standard work, Flow and layout, Pull systems, Ergonomics and safety, Set up reduction, Mistake proofing, Total productive maintenance, Inventory management
Day 6 – Lean in the office Offices – what good looks like Planning and implementing lean in the office using Stabilise, Standardise and Visualise roadmap Lean in the Office – valid tools including Flow systems, value stream mapping, process mapping, office layout, pull systems, visual controls, office 7 wastes, 5S work are organisation, standard work, mistake proofing and balancing schedules.
Day 7 and 8 Design for Six Sigma – new concepts – The process improvement roadmaps (PDCA and DMAIC) are aimed at fixing existing ‘broken’ processes – Day 7 and 8 focus on the design of new concepts for service and product applications using the Design for Six Sigma roadmap Define , Measure, Analyse, Design and Verify (DMADV). If you are designing a new process or substantially refreshing one then this is an innovative technique that uses the houses of quality to provide a connection between the customer needs, functional requirements, design features and process specifications. It is a powerful process and has been used to design new concepts for everything from airbags to theme park dinosaurs!
The following topics are covered using a case study design concept project:
- Design for Six Sigma overview
- House of Quality #’s 1 and 2
- Generating design concepts inclu creativity tools, theory of innovative solutionsTRIZ and morph matrix
- Evaluating Design Concepts incl Pugh matrix
- House of Quality #’s 3 and 4
- Design simplification
- Design scorecard
- Prototyping, pilots and pre-production
- Plus project examples
Each day starts (from Day 2) with a short exam covering the previous module so that you can study as you go rather than one large exam at the end and get instant feedback to see if you’ve understood the concepts.