Certified Lean Six Sigma® Black Belt

Module 1: review continuous improvement and Lean Six Sigma

• What is continuous improvement? Definition, challenges, benefits and practical examples.
• Problem-solving methodologies: general approach, the 5 Whys and the Ishikawa diagram.
• Continuous improvement challenges: competitiveness, sustainability and resistance to change.
• Choosing an improvement strategy: criteria, examples and alignment with business strategy.
• Main continuous improvement methodologies: Lean, Six Sigma, TQM and others.
• Introduction to Lean Six Sigma: history, fundamental principles, benefits and applications.
• Lean Six Sigma pillars: customer focus, process optimisation, employee involvement, supplier relationships, measurement and continuous improvement.
• The connection between Lean and Six Sigma for operational excellence.

Module 2: advanced understanding of DMAIC — Define and Measure

• Define phase
  • Defining critical customer requirements: Voice of the Customer.
  • Precisely describing the problem: problem statement and customer value analysis.
  • Defining SMART objectives: Specific, Measurable, Achievable, Realistic and Time-bound.
  • Assessing project benefits: financial gains, improved quality and customer satisfaction.
  • Building the project team: roles, responsibilities and required skills.
  • Building a SIPOC: Suppliers, Inputs, Process, Outputs and Customers.
  • Planning project stages: Gantt charts, milestones and resources.
  • The project charter and formal documents specifying objectives, scope, resources and responsibilities.
  • Phase review or tollgate: validating stages and moving to the next phase.
• Measure phase
  • Key performance indicators: definition, selection, monitoring and dashboards.
  • Data collection tools: questionnaires, observations, direct measurements and databases.
  • Basic statistical tools: histograms, Pareto charts, scatter plots and process capability analysis.
  • Measurement system analysis: assessing data accuracy and reliability.

Module 3: in-depth understanding of DMAIC — Analyse and Improve

• Analyse phase
  • Cause analysis tools: Ishikawa diagrams, 5 Whys, root cause analysis and cause trees.
  • Advanced statistical tools: hypothesis testing, including t-tests and ANOVA, linear regression and correlation analysis.
  • Building decision trees: selecting solutions based on risks and benefits.
  • Failure modes, effects and criticality analysis (FMECA).
• Improve phase
  • Brainstorming and creativity techniques: generating ideas and creative approaches.
  • Design of experiments: principles, applications, design and results analysis.
  • Selecting and implementing solutions: evaluating options, selecting the best solution and implementation planning.
  • Lean principles and tools: 5S, Kaizen, Value Stream Mapping, Kanban and Poka-Yoke.
  • Value and flow analysis: Lean metrics, value analysis, flow and pull.
  • Kaizen events: organising and facilitating continuous improvement workshops.

Module 4: in-depth understanding of DMAIC — Control

• Control phase
  • Statistical process control plans: control charts, identifying variation and controlling the process.
  • Performance monitoring indicators: dashboards, reports and results tracking.
  • Process standardisation: documentation, procedures and work instructions.
  • Lessons learned and learning: retaining knowledge and continually improving the improvement process.
  • Lean metrics and the benefits of realisation and validation plans.
  • Control chart theory, creating control charts and specialised control charts.
  • Response surface analysis.

Module 5: use specific tools and techniques

• Agile project management and its compatibility with Lean Six Sigma.
• Project monitoring tools: Kanban and dashboards.
• Effective communication in Lean Six Sigma projects: stakeholder communication and effective presentations.
• Leadership and team facilitation: motivation, delegation and conflict management.
• Change management: supporting change, communication and training.
• Advanced statistical tools: logistic regression and survival analysis.
• Problem-solving techniques: 8D and FMECA.
• Project management tools: PERT and CPM.
• Soft skills: negotiation, effective presentation and conflict management.

Module 6: prepare for the Six Sigma Black Belt exam

• Introduction to different Lean Six Sigma certifications and their criteria.
• Review of key points covered throughout the course.
• Detailed introduction to exam structure, format and topics.
• Advice and tips for exam success, including approach and time management.