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Black Belt Training/ Certification that includes facilitation of up to twelve (12) candidates over 6 months.  Participants learn advanced problem solving tools and techniques using Six Sigma or TQM problem solving approaches and each complete an improvement project.

(Cost: $78,000)($54,000 if candidates certified from above Green Belt Training/ Certification)

 

Purpose:

The Black Belt Certification Program is designed to provide additional specialized training for employees, in order to develop each into an internal consultant and prepare them to lead, facilitate, or assist improvement teams or efforts in applying Lean Six Sigma Tools and Techniques.  It is also designed to enhance employees’ technical knowledge in the areas of statistical tools and techniques in the work place, to analyze data in order to determine whether their business priorities are in control and capable of consistently meeting customer requirements. This training follows “basic” problem solving and process improvement training. (See Black Belt Candidate Profile attached.)

 

Program Overview:

The Candidate will be exposed to a practical and systematic methodology for day-to-day problem solving. Black Belt certification can be accomplished by completing the following requirements:

A.  Candidate should be a certified Green Belt Candidate and have completed basic Problem solving training (DMAIC methodology) along with at least 1 successfully completed improvement project.

B. Complete advanced statistical tools Training modules (12 days) (see proposed training modules).

C.  Complete an Improvement Project through all Process steps (i.e. 5 step DMAIC Process) and demonstrate the advanced tools and techniques.

D. Successfully complete Black Belt Exam with a score of  70 or better. (Exam is open book and Candidate can retake exam if needed.)

E. Candidate and project approved by Master Black Belt Instructor- Project One on One Review Sessions will incorporate a review of the candidate’s project and how the candidate has incorporated the previous project review’s feedback and training.

 

Desired Black Belt Candidate Characteristics:

1.      Strong Analytical Skills including familiarity with basic algebra, computer spreadsheets (Excel, Visio, etc.), construction of various basic graphs (line, bar, pie, Pareto, etc.)

2.      Future Availability to Teams – Candidates should be able to be available within the next 1-2 years to be available to teams at their locations for interval consulting and/or leading problem solving or process work efforts. Because Black Belts are needed to help other teams, existing managers with very little projected future time availability for others would not be good candidates.

3.      Future Leadership Potential – While this is not essential, it is a recommended characteristic to ensure that the organization will continue to grow toward its vision.

4.      Available Time for Training and Project – This training includes 12 one-day workshops along with project work.  Each candidate needs to have about 5-10 days per month minimum to commit to this effort.

 

Black Belt One-Day Training Modules

 

Session 1: 

DMAIC-Define

 

  • Separating true problems from other concerns

  • Problem solving concept “funnel”

  • Object/defect problem simplification technique

  • Types of line graph indicators (simple, cumulative and time ending)

  • How to select the “best” line graph indicator

  • Target methodologies

  • DMAIC Story examples and exercises

  • “Live” DMAIC Story exercise with attending employees

 

Session 2:

DMAIC-Measure

     

  • Electronic Spreadsheets (what, where, when and who stratifications)

  • Paretos – various applications

  • Histograms – various applications

  • Various types of stratifications (bar graphs, pie charts, line graphs, flow charts)

  • Target setting methodologies

  • Convert “reduction” problem to a “zero” problem

  • DMAIC Story examples and exercises

  • “Live” DMAIC Story exercise with attending employees

 

Session 3:  

Data-driven Goal Deployment and Goal Review Process

 

  • Demonstration of the methodology to apply the tools learned in Sessions #1 and #2 to deploy the goals of an organization to ensure cause and  effect alignment of the cascaded goals and improvement initiatives to the top level organizational goals

  • Review of the high level business review line of questioning that will be supported by the analysis techniques learned in this course

 

Session 4:

DMAIC-Analyze (Quantitative)

 

 

  • Analysis (concept/definitions)

  • Fishbone (types and when to use)

  • Cause and effect diagram with the addition of cards (CEDAC)

  • “Single Case Bore” analysis

  • Verification techniques

  •  Scatter diagram

  • Contingency table/ Chi Square Test

  • DMAIC Story examples and exercises

  • “Live” DMAIC Story exercise with attending employees

 

Session 5: 

DMAIC-Improve

 

  • Countermeasures matrix (types and applications)

  • Barriers and aid analysis

  • Gantt charts (action plans)

  • “Before and after” measurements

  • Confirming that results are due to countermeasures

  • DMAIC Story examples and exercises

 

Session 6:

Decision Analysis

 

  • Management processes (problem/decisions/plans)

  • Full decision analysis process (scope/objectives/alternatives/risk)

  • Partial decision analysis

  • “Try and track” DMAIC Stories

  • Improvement Story example and exercises

  • “Live” Improvement Story exercise with attending employees

 

Session 7:

Control

 

  • Probability (Random) Sampling

  • Process stability (control chart types and interpretation)

  • Process capability and flexibility (histograms/frequency chart)

  • Improvement Story examples and exercises

  • “Live” DMAIC Story exercise with attending employees

 

Session 8:

Creative / Breakthrough Thinking

 

  • Ideation (concept)

  • Creative thinking (concept, barriers, techniques, exercises)

  • Breakthrough thinking (concept, techniques, exercises)

  • Redesign/re-engineering (concept, techniques)

  • Improvement Story examples and techniques

 

Session 9:

Process Flow Charting

 

  • Construction rules of flow charting

  • Stratification techniques using flow charts (quantitative analysis)

  • Quality Delivery System (QDS)

  •  Macro vs. micro flow charts

  • Qualitative analysis using flow charts

  •  Flow chart simplification techniques

  • Improvement Story examples and exercises

  • “Live” flow charting session with attending employees

 

Session 10:

Surveys

  

  • How to plan “surveys” to aid in monitoring and problem solving

  • Affinity process for focus groups

  • Aligning surveys with process flow charts

  • Use of surveys to stratify data, identify root causes and identify countermeasures

  • Methods to make surveys more efficient and useful upon completion

  • DMAIC Story examples using surveys

  • “Live” survey development session with attending employees and subsequent DMAIC Story  application

 

Session 11:  

Team Diagnostics

 

  •  Identifying appropriate management processes

  • Diagnostics (concept:  should vs. actual)

  • Recognizing team performance variances (when teams are off track)

  • “Basic fixes” (to put team back on track)

  • Team diagnostic case study exercises (to include existing/past teams)

 

Session 12:

Advanced Root Cause Verification Techniques

 

  • Correlation and Regression Analysis

  • Multiple Regression, Logistic Regression

  • Hypothesis Tests, p-Value, t-Test

  • Analysis of Variance (ANOVA), Contingency Tables

  • Design of Experiment (DOE)

 

 

 

 

 

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