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USD 3100

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About the course

This instructor-supported course covers the complete Lean Six Sigma Black Belt body of knowledge. As a Black Belt, you are able to lead any team across your organization in executing process improvement projects. If your goal is to master this skill set and improve your value as an employee and organizational leader, then this course is for you.

Outline

The Ohio State University Fisher College of Business

Session 1: Introduction To Lean Six Sigma

  • Introduction
  • Higher Standards for Higher Performance
  • Input Determines Output
  • Lean Six Sigma Defined
  • What's In a Name?
  • The 5 Lean Principles
  • The 8 Forms of Waste
  • Success Stories
  • The Sigma Level
  • The 99.9% Problem
  • Introduction to EngineRoom®
  • DNA of a Champion
  • Lean Six Sigma Framework
  • DMAIC - The Improvement Process
  • Lean and DMAIC
  • Thought Process Mapping - Toolset
  • Organizing for Success
  • Working Relationships
  • Critical Success Factors
  • Skill Check

Session 2: Define I - Starting A Project and Leading Teams

  • Getting Started - Project Initiation
  • Balanced Scorecard Toolset
  • Project Selection Toolset
  • Project Charter Toolset
  • Project Planning & Tracking Toolset
  • Leadership Thinking
  • Robot Leadership
  • Fueling The Improvement Engine
  • Leadership Characteristics
  • Practice, Study and Reflection - Learning by Modeling
  • Leading Teams
  • Developing an Effective Team
  • Improving Team Development
  • 4 Conversations Toolset
  • Leading Change
  • Leading Change - Continued
  • Success Factors For Effective Change Management
  • Leader Standard Work Toolset
  • Stakeholder Analysis - RACI Matrix
  • Leadership Reflection
  • Exercises and Quiz

Session 3: Define II - Voice of the Customer

  • Voice of The Customer
  • Focus on The Customer
  • Understanding Customer Requirements
  • Where to Go For Customer Requirements
  • Conducting Surveys
  • Survey Considerations
  • Surveys - Sampling Frame
  • Structuring Survey Questions
  • The Degree of Uncertainty in Sampling
  • Guideline for Margin of Error
  • Affinity Diagram Toolset
  • CTQC Tree Diagram Toolset
  • Operational Definition Toolset
  • Voice Of The Customer As Specifications
  • QFD Toolset
  • Exercises and Quiz

Session 4: Define III - Mapping the Process

  • Drawing a Process Picture
  • Process Thinking
  • The Source of Value
  • The Source of Value: Gemba
  • Process Mapping - Overview
  • Process Mapping (SIPOC) Toolset
  • Flow Charts
  • Value-Added Flow Charts
  • Spaghetti Charts
  • Takt Time
  • Value Stream Mapping Toolset
  • Define Tollgate - Progress Review
  • Exercises and Quiz

Session 5: Measure I - Measurements and Basic Statistics

  • Measurements and Basic Statistics
  • Business Problem Solving
  • Basic Statistical Terms
  • Descriptive and Inferential Statistics
  • Measurements
  • Discrete vs. Continuous Measurements
  • Measurement Subjects
  • Graphical Summaries
  • Pareto Chart Toolset
  • Histogram Toolset
  • Understanding Variation
  • Measuring Central Tendency
  • Quantifying Process Variability
  • The Normal Distribution
  • Exercises and Quiz

Session 6: Measure II - Measurement System Analysis

  • Measurement System Analysis - Introduction
  • Measurement as a Process
  • Cause & Effect Matrix Toolset
  • The Analysis of Measurement Systems
  • The Requirements of Measurement Systems
  • Variable MSA - Gauge R & R
  • MSA - Graphing
  • Attribute Measurement System Analysis
  • Calibration of Measurement Systems
  • Collecting Data
  • Developing a Sampling Plan
  • Baseline Performance
  • Derivative Performance Metrics - Throughput Yield
  • Derivative Performance Metrics - Rolled Throughput Yield
  • Calculating the Sigma Level - Toolset
  • Exercises and Quiz

Session 7: Measure III - Charting Process Behavior

  • Introduction - Charting Process Behavior
  • Trend Chart Toolset
  • SPC - Introduction and Background
  • SPC - Introduction to Control Charts
  • SPC - Control Chart Limits
  • SPC - More On Control Limits
  • Implementing SPC
  • SPC Chart Selection
  • Rational Subgrouping Toolset
  • X and Moving Range Charts - Toolset
  • Attribute Control Chart Toolset
  • X-bar and R Chart Toolset
  • Process Capability Toolset
  • The Sigma Level Revisited
  • Measure Tollgate - Progress Review
  • Exercises and Quiz

Session 8: Analyze I - Identifying Potential Root Causes

  • ANALYZE I - Introduction
  • Finding The Root Cause
  • Cause & Effect Diagram Toolset
  • Alternative To The Cause & Effect Diagram
  • 5-Why, 1-How
  • A Combination of 5-Why, Pareto, and Trend Charts
  • Box Plots Toolset
  • Scatter Plot Toolset
  • Correlation and Regression Analysis
  • Multiple Regression Toolset
  • Binary Logistic Regression Toolset
  • Factors In Determining Sample Size
  • Estimating Population Mean
  • Exercises and Quiz

Session 9: Analyze II - Hypothesis Testing

  • ANALYZE II - Introduction
  • Introduction to Hypothesis Testing
  • The Process On Trial
  • The Hypothesis - Accept or Reject?
  • Types of Error
  • Power Analysis
  • Power Analysis - Factors
  • Hypothesis Testing
  • Confidence Intervals
  • Treatment Comparisons - Control Charts
  • Comparing One Proportion to a Standard
  • Comparing Two Proportions Toolset
  • Comparing Multiple Proportions - Chi-Square
  • Comparing One Mean to a Standard - t-test
  • Comparing Two Means - t-test Toolset
  • Comparing Multiple Means - ANOVA /F-test Toolset
  • Comparing One Variance to a Std. - Chi-Square
  • Comparing Two Variances - F-test Toolset
  • Parametric vs. Non Parametric Tests
  • Non Parametric Toolset
  • Hypothesis Testing Learning Lab
  • Exercises and Quiz

Session 10: Analyze III - Design of Experiments

  • Design of Experiments - Introduction
  • Design of Experiments - History
  • Design of Experiments - Components
  • Design of Experiments - Principles
  • Design of Experiments - Purpose
  • Design of Experiments - Process
  • Design of Experiments - Guidelines
  • Selecting the Right Design
  • Blocking
  • Blocking and Tackling
  • Faster Deliveries Through Experimentation
  • Beyond One-Factor Experiments
  • Two Level Full Factorial Toolset
  • Two Level Fractional Factorial Toolset
  • General Factorial Toolset
  • DOE Power and Sample Size
  • Designing An Experiment To Save The Kingdom
  • Better Pizza Through Design of Experiments
  • Designing Experiments to Sell More Coffee
  • Additional Subjects
  • Analyze Tollgate - Progress Review
  • Design of Experiments Exercises and Quiz

Session 11: Improve

  • Improve
  • Design for Lean Six Sigma (DFSS)
  • Benchmarking
  • Brainstorming
  • Narrowing Down The List of Ideas
  • FMEA Toolset
  • Error-proofing
  • Prioritizing and Selecting a Solution
  • The A3 One-Page Report
  • Continuous Flow Toolset
  • Quick Changeover Toolset
  • Cellular Processing Toolset
  • Leveling Production (Heijunka)
  • The Theory of Constraints (TOC) Toolset
  • Pull System Overview
  • Pull Scheduling
  • Core Process Pull Toolset
  • Replenishment Pull Overview
  • Kaizen Toolset
  • Corrective Action Matrix
  • Piloting a Solution
  • System Dynamics Toolset
  • Improve Tollgate - Progress Review
  • Exercises and Quiz

Session 12: Control

  • Control
  • Control Charts Revisited
  • The Process Control Plan
  • More On FMEA
  • Visual Management
  • 5-S Approach
  • CHECK Process
  • Total Productive Maintenance
  • TPM Objectives & Benefits
  • TPM Metrics
  • TPM Core Elements
  • TPM Maintenance Activities
  • Best Practices and Lessons Learned
  • Standardized Work - Documenting Process Changes
  • Ending the Project
  • Control Tollgate - Progress Review
  • Exercises and Quiz
  • Course Completion
  • The Lean Six Sigma Journey

Case studies and examples can be customized to focus on Manufacturing (default), Healthcare, Financial Services, and Services applications.

Lean enterprise topics include value stream mapping, continuous flow, line balancing, and others.

No pre-requisites.

Course access period is 365 days.

This course includes EngineRoom® Excel-based data analysis software and instruction on how to use EngineRoom®. Also offered for Minitab® version 16 (Minitab® software must be purchased separately).

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