SIX SIGMA BLACK BELT COURSE OUTLINE

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SIX SIGMA BLACK BELT COURSE OUTLINE
A. The Environment for Six Sigma Projects
Setting the Stage 1. The Hidden
Factory 2. The Quality Lever 3.
The Demanding Nature of Customers 4. The
Nature of Process Variation B. The DMAIC
Process 1. Six Sigma Project Selection
2. The Process, Phases and Steps of DMAIC
3. DMAIC Steps 1 and 2
C. The Voice of the Customer 1.
Overview of the Quality Function Deployment (QFD)
Phases 2. QFDs Phase 0 The Voice of
the Customer a. The Klein model
of customers perceptions of quality b.
Techniques for gathering and analyzing customer
data c. Sources of customer data
d. Guidelines for creating and asking
better survey or
interview questions e. Using
the QFD matrix to translate CCRs into CTQs
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D. Basic Tools of Phases I and II 1.
SIPOC2. Team Charter3. Sampling4.
Checksheets
E. Introduction to Team Building (Optional)1.
Benefits2. Integrated Teams3.
Development Stages4. Team Dynamics5.
Product Meeting Guidelines6. Team Roles7.
Meeting Skills8. Giving and Receiving Feedback
F. Descriptive Statistics 1.
Charting Data Over Time 2. Summary Data
Patterns and Histograms 3. Measures of
Central Tendency and Dispersion 4. The
Normal Distribution Curve 5. Process
Control vs. Process Capability
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6. Boxplots 7. Point and
Interval Estimates 8. Confidence
Intervals, with Decision Tree (Optional)
a. Z Distribution on Means
b. t Distribution on Means c.
?2 Distribution on Variation 9. Tests
for Normality 10. Typical 6 ? Performance
Metrics (p. 186-193) a.
Defect-Based b. Capability-Based
c. Sigmas
G. Measurement Variation Analysis 1.
Repeatability 2. Reproducibility
3. Procedure for Conducting 4.
Interpreting Results and Follow-up Actions
5. Accuracy, Stability, Linearity
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H. The Steps and Basic Tools of Phase III
1. The Basic Tools for Data Collection
a. Tally sheets/Checksheets b.
Histograms Pareto 2. The Basic Tools
for Data Analysis a.
Teaming/Brainstorming b. The 5
Why?s c. Root Cause Analysis
d. Cause Effect Diagram (Fishbone)
e. Scatter Diagram f.
Charting Data over Time g.
Multi-Vari Charts h. Process
Mapping i. Statistical Testing
j. Design of Experiments
I. Process Mapping 1. The Basics of
Process Mapping 2. Creating the As-Is
Process Map
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Week 2
3. Analyzing the As-Is Process Map
a. Value-Added Analysis b.
Streamlining c. Reduction of Cycle
Time, Distance Traveled, Number
of Steps d. Identification of
Breakdown Opportunities 4. Creating the
Should-Be Process Map 5. The Process
Mapping Scorecard
J. Statistical Population Tests 1.
Basic Concepts and Terms 2. Statistical
Risks 3. One- and Two-Tail Tests
4. Inference Test Decision Trees 5. Z
Test on 2 Means 6. t Tests on 2 Means
7. ?2 Test on 2 Variances 8. F
test on 2 Variances 9. ?2 Goodness of
Fit Test
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10. Tests on Multiple (? 3) Means and
Variances a. ANOVA b.
ANOM c. Bartletts 11. Tests on
Proportions 12. Determining Sample Size 13.
Non-Parametric Tests 14. Examples and Exercises
K. Introduction to Design of Experiments
1. Basic Experimental Design and Analysis
a. Orthogonal Arrays and Fractional
Factorials b. Main Effects and
Interactions c. Level Averages and
Response Graphs d. Confounding
e. Mixed-Level Designs
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2. Intermediate Design and Analysis a.
Other Design Considerations (Blocking,
Replications, Randomization, Centerpoints,
etc.) b. 2-way and 3-way Designsc. Analysis
of Variance (ANOVA)d. Signal-to-Noise Ratios
(Static)e. Parameter Design and Robustnessf.
Variation Reduction and Centering of the
Meang. Control and Tuning Factorsh. The
Dynamic Case Signal-to-Noise Ratiosi.
Introduction to Mixture Designsj. Application
of the Quality Loss Function in Tolerance Design
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Week 3
L. Statistical Process Control (SPC)
1. SPC Concepts a. Quality
Characteristics b. The Nature of
Variation c. Tier Chart
2. Variables Control Charts a.
Application of the Central Limit Theorem
b. Components of a Control Chart
c. Analyzing SPC Charts for Patterns of
Variation d. Creating and Plotting
SPC Charts e. Determining Process
Capability 3. Attributes Control
Charts a. Conformance to
Specification b. Selecting the
Type of Attribute Chart c. p
Charts d. np Charts
e. c Charts f. u Charts
g. Attributes Inspection Capability
Studies 4. Other Types of Control
Charts a. Variations of
Conventional Charts b. Short-Run
Charts
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Week 4
M. The Steps and Basic Tools of Phase IV
1. The Basic Tools for Selecting Solutions
a. Multi-Voting b.
Decision-Making Matrix 2. The Basic
Tools for Planning Implementing Solutions
a. Force Field Analysis
b. Project Status Reports
N. Failure Mode and Effects Analysis (FMEA)
1. Overview of the Types of FMEAs
2. Using Process FMEAs for Planning Process
Controls a. Purpose and Role of
Process FMEAs b. Step-by-Step
Creation of a Process FMEA c.
Manufacturing Controls d.
Interpreting and Using a Completed Process FMEA
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O. Introduction to Correlation and Regression
Analysis 1. Introduction 2.
Scatter Diagrams 3. Least-Squares
Estimating 4. Creating and Using the
Regression Line 5. Standard Error of
the Estimate 6. Confidence Intervals
7. Coefficients of Determination and
Correlation 8. Inference Tests Used in
Regression and Correlation 9. Model
Fitting and Residuals 10. Other
Regression Models (Non-Linear Multi-Variate)
11. Regression Examples and Exercises P.
The Steps and Basic Tools for Monitoring and
Controlling Improvements (? V) 1.
Poka-Yoke 2. 5 Ss 3.
Statistical Process Control (SPC) 4.
Failure Mode and Effects Analysis (FMEA)