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Lean Six Sigma: Black Belt

COURSE TYPE

Advanced

Course Number

3993

Duration

Multiple*

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This workshop is designed for Lean Six Sigma team leaders and expands upon the skill set taught in the Green Belt certification. The coursework includes instruction on modules in practical DMAIC applications, Failure Mode Effects Analysis, Advanced Lean, Advanced DOE, SPC for non-normal distributions, Optimization, Scheduling & Sequencing, effective and efficient teamwork strategies, as well as a variety of other tools and analysis methodologies. The PhD professors offer practical experience in guiding students through this workshop, assisting with the attendee case-study assignments.

Training accredited by Thayer School of Engineering at Dartmouth:

Professional certification is a process in which a person proves that he or she has the knowledge, as a basis, for performing a specific job. The proof comes in the form of a certification earned by passing quizzes, an exam, case studies, actual case or some combination of these items that are provided by an accredited organization. Accreditation is recognition that an educational institution has a certain standard of quality that other reputable organizations will honor. Without accreditation the certification provider may not provide the participant lasting value. Therefore, it is imperative that you receive your certification from a trusted, accredited institution. Dartmouth College, founded in 1769, is accredited by the Commission on Institutions of Higher Education (CIHE) of the New England Association of Schools and Colleges (NEASC). Accreditation is a non-governmental, non-profit, self-regulatory, peer review process based on rigorous standards.

Workshop Schedule:

*20 – (4-hour sessions); (2 sessions per week for 10 weeks), sessions run 10:00 am to 2:00 PM Eastern Time (approximately 80 hours of training) plus you must do two LSS case studies, (approximately 80 hours homework). Lean Six Sigma Black Belt Certification from Thayer School of Engineering at Dartmouth will be awarded upon successful completion of coursework, test, and two case studies. Please review the PDF for the Schedule options: Lean Six Sigma Black Belt Schedule

You Will Learn How To

  • Apply a wide range of process improvement techniques
  • Think about your organization as a collection of processes, with inputs that determine the output
  • Apply the five-step DMAIC model to organize process improvement activity
  • Successfully lead complex process improvement projects
  • Deliver meaningful, bottom-line operational excellence to the organization

Important Course Information

Who would benefit from this training?

The Black Belt workshop is for those individuals that want to gain an in-depth knowledge of lean six sigma, and also be able to manage a lean six sigma project.

Prerequisites:

Participants must have completed the Green Belt program or have college level statistics (in the last 4 years) and are highly confident in their statistics capability before taking this workshop. We can evaluate a person’s background if needed – at no extra charge.

Students are highly recommended to have a copy of the Black Belt Course Manual, in either Paper or PDF copy, to use as reference.

Homework:

Students must complete two case studies (choosing from manufacturing, finance, or healthcare) within 10 days of the last class (approx. 80 hours of homework). You will receive all case studies before the workshop begins, and will work on them over the duration of the training.

Software/Hardware:

A laptop with a functional copy of a statistical analysis package, Minitab, will be needed for this workshop. A trial copy of Minitab is usually sufficient if you wait to sign up for Minitab just prior to using it - to make sure the trial does not run out before you do the case studies and test. Minitab must run on a Windows PC.

A headset with microphone is required, as using built-in speakers/microphone causes echo issues. Headsets give participants complete interaction with the instructor and other students.

Course Materials:

Students will be provided with a pdf of the class materials.

All sessions are recorded, placed in a dropbox, and provided to participants for download to a computer in the event of a missed class or for review in the future.

Exam Information: This take home exam is required. You must show your own original work on the exam and must work independently. Contact the instructor for help and guidance; do not contact other participants. You must complete the exam and email it to the instructor within 10 business days of the last session on day 20. Those who do not return the exam within 10 business days will not be eligible for the LSS Black Belt Certificate (unless advanced exception was granted by Dr. Lasky).

This is an open notes exam so you can use all of the material that the instructors have provided to you. The exam will be primarily question and answer format and should be completed in approx. 20 hours. It is a pass/fail exam.

Certification Information:

Dartmouth College, Thayer School of Engineering, will issue a certificate of completion, in pdf format, to participants who successfully complete the case study and pass the take home quiz.

Course Outline

  • Review Lean Six Sigma (LSS)

Learn Basic Definitions (Process, Lean, Six Sigma)

The DMAIC Model with Gate Reviews

Basic Tools (Problem Statement, SIPOC)

Performance Based Metrics, DPU, DPMO

Practice with examples

  • Voice of Customer (VOC)

Describe the importance of VOC, and VOB

Define and clarify CTQ and COPQ

Understand how to segment Customers

Learn how to capture Voice of Customer

Describe the development of Critical Customer Requirements (CCR)

Create a CCR Tree - Practice

Learn how to use Kano Analysis

  • Project Justification – Building the Business Case Utilizing the VOC

Define the Business Case – Why?

Learn to utilize the business case to justify the need for the project

ROI of Quality / Project ROI

Pitching the Case – VOC & VOB

An Example

  • Performance Management & Team Accountability

Performance management as a System

Our responsibility as a Leader

Setting expectations

Accountability! It means a lot

Holding one Accountable

  • Project Control & Change Management

Developing and revising the Project Charter

Project management Fundamentals

Managing personal and organizational change

Red-Yellow-Green status and action plans

Using the A3 tool to report project status

Risk response

Managing deliverables: requirements, testing, implementing, passing ownership

Managing change at the individual, team and organizational level

  • Statistics Refresher

Common and special cause variation

Variation and the normal curve

Types of Data (Attribute, Variable (continuous))

Measures of Central Tendency

Concept of Standard Deviation

Process Capability: Cp and Cpk

  • Advanced Stats

Confidence Interval Review

Hypothesis Testing Review

Sample Size

Type II Error and Power

Hypothesis Testing of Variance

Tolerance and Prediction Intervals

Tests on a Proportion

Statistical Inference for Two Samples

Using Minitab to Solve Advanced Stats Problems

Sampling Strategies to Determine Quality Levels

  • Advanced SPC

SPC Review

Advanced Gage R&R

Shewhart Rules

SPC for Non Normal Data

Minitab Examples

  • Technical Estimating

Importance

Tips

Examples

  • Intermediate DOE

DOE Review

Analysis of Variance

Blocks

Full Factorial DOE

  • Intermediate DOE

Fractional Factorial DOE

Taguchi DOE

Central Composite Design

Response Curve Methodology

Multiple Linear Regression

Numerous Minitab Examples

  • Lean Culture

Building a lean culture

5S

Visual Workplace

Standardized Work

  • Kaizen Planning

What is a Kaizen?

5s Kaizen Example

Kaizen Event Flow Example

When to Kaizen

When Not to Kaizen

Chartering a Kaizen

  • Controlling Defects

Mistake proofing

Control Plans

Response Plans

  • 8D for Containment & Control

8D – The steps to root cause and control

  • Other Process Tools & Techniques: Optimization

Introduction to Optimization

Review Key Definitions

Linear Programming

Integer Programming

Programming with Excel

Applications

  • Other Process Tools & Techniques: Scheduling Definitions and Jargon

Overview of Different Production Scheduling Environments (Single machine, Parallel machine, Flow shops, Others)

Typical Assumptions used in Scheduling

Performance Measures

Scheduling Techniques (Algorithms and Heuristics)

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Tuition

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Standard

$4855

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Training Hours

20 half day sessions (two 4hr sessions per week, for ten weeks); 10:00 am to 2:00 pm Eastern Time

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