Continuing Education

Lean Six Sigma


Black Belt Certification Training

Instructor: Gerald Bose, MS, Lean Six Sigma BB.

Prerequisite: Attend free session, Introduction To Lean Six Sigma Black Belt Certification, Wed, Sep 17, 2014, 6:30-8:30 pm (registration required.)

Attaining Lean Six Sigma (LSS) Black Belt Certification is an investment in your career and your future, as well as a means to improve an employer’s profitability. Brookdale’s seven-month program, based on the American Society of Quality Six Sigma Black Belt Body of Knowledge (www.ASQ.org), trains individuals in this highly marketable quality management methodology that is in demand in many industries, such as manufacturing, pharmaceuticals, health care, financial services, insurance, and information technology.

Understand how to improve the efficiency and effectiveness of key processes through the application of tried and proven LSS principles. Candidates should lead at least one LSS project while studying traditional DMAIC methodology (define, measure, analyze, improve, and control). A good qualifying project is one that demonstrated positive change for the selected business process, impacted the way process owners perform their jobs, and had measurable, positive impact on your company’s business metrics.

Fee includes instructor mentoring outside of classroom time on your LSS project(s). Students acquire a practical working knowledge of Lean Six Sigma tools and techniques and understand the key concepts in ASQ’s Six Sigma Black Belt Body of Knowledge as preparation for the ASQ Six Sigma Black Belt certification examination. Requires no prior knowledge of statistics or Lean Six Sigma. 35 SESSIONS

Taking this course does not constitute, nor imply, the successful passing of the ASQ Certified Six Sigma Black Belt exam.

Recommended Background: Black Belt candidates have good math and reading comprehension skills, are experienced problem solvers, have proven interpersonal skills, and are comfortable using Microsoft Office including MS Project or equivalent. Many candidates may be pursuing an associate’s or bachelor’s degree in business, engineering, information technology, or a science. Also, technical trade professionals—for example, machinists, pipefitters, mechanics, or maintenance technicians—are excellent candidates.

Required texts available for purchase in College Bookstore.

Dates and Times: Tues, Oct 14, 2014 to May 19, 2015, 5:30-9:30 pm (no class Dec 30; snow make-up day May 26)
Fee and Code: $3,999 (plus texts listed below). Fee includes one year timed version of Minitab 16 and Quality Companion 3 software. XBUSM 231 W


Course Outline (topics/order may vary):

1: Lean Six Sigma Overview

  • Introduction
  • Lean Six Sigma Defined
  • What’s In a Name?
  • Success Stories
  • Input Determines Output
  • The 99.9% Problem
  • The Sigma Level
  • Six Sigma Framework
  • Lean Framework
  • DMAIC – The Six Sigma Improvement Process
  • Organizing for Success
  • Next Steps

2: Define Tools

  • Project Selection
  • The Project Charter
  • Project Scope / Goals
  • Balanced Scorecard
  • Project Planning and Tracking
  • Leadership Thinking
  • Leadership Characteristics
  • Leading Teams
  • Team Dynamics
  • Effective Change Management
  • Focus on The Customer
  • Capturing The Voice Of The Customer
  • Establishing Customer Requirements
  • Affinity Diagrams
  • CTQC Tree Diagram
  • Voice Of The Customer As Specifications
  • Stakeholder Analysis – RACI Matrix
  • Process Thinking
  • Process Mapping (SIPOC)
  • Flow Charts
  • Value Stream Mapping
  • Define Tollgate/Progress Review

3: Measure Tools

  • Measurements & Statistics
  • Measurement As A Process
  • Calculating the Sigma Level
  • Understanding Variation
  • Process Variability
  • The Normal Distribution
  • Process Dependent & Independent Variables
  • Problem Solving
  • Measurement System Analysis (MSA)
  • Variable MSA – Gauge R & R
  • Trend Charting
  • Histograms
  • Collecting Data
  • Developing Sampling Plans
  • Calibration of Measurement Systems
  • Process Validation
  • Intro to MiniTab
  • Performance Metrics — Throughput Yield
  • Baseline Performance
  • Statistical Process Control (SPC) Overview
  • X and Moving Range Charts
  • Pareto Charts

4: Analyze Tools

  • Cause & Effect Diagram
  • 5-Whys
  • Scatter Plots
  • Hypothesis Testing
  • Confidence Intervals
  • Treatment Comparisons — Control Charts
  • ANalysis of VAriables (ANOVA)
  • Failure Mode Effect Analysis (FMEA)
  • Correlation and Regression Analysis
  • Design of Experiments (DOE)
  • DOE Power /Sample Size
  • Selecting the Right Design
  • Beyond One-Factor Experiments
  • Waste / Non-Value Added Analysis
  • Spaghetti Diagrams

5: Improve Tools

Brainstorming / Idea Generation

  • Benchmarking
  • Design for Lean Six Sigma (DFSS)
  • Error-proofing
  • Prioritizing and Selecting a Solution
  • Continuous Flow Tools
  • Cycle Time Reduction
  • Standardized Work
  • Quick Changeover
  • Cellular Processing
  • Theory of Constraints (TOC)
  • Pull Systems
  • Kaizen Events
  • A3 Communications
  • Plan-Do-Check-Act (PDCA)
  • Implementation Planning
  • Piloting a Solution

6: Control Tools

  • Control Charts Revisited
  • Risk Mitigation (FEMA)
  • Visual Controls
  • Total Productive Maintenance (TPM)
  • 5-S Approach
  • Performance Metrics
  • Control Plan
  • Operations Excellence (OpEx)
  • Key Performance Indicators (KPI)
  • Best Practices/Lessons Learned
  • Completing / Ending the Project
  • The Lean Six Sigma Journey
  • Course Completion
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