Lean Sigma is an improvement management system adopted by many enterprises to realize the vision of operational excellence. In the hybrid platform of Lean and Six Sigma, Lean Sigma Black Belts are equipped with dual capabilities from these two proven operational strategies, helping organizations to achieve operational excellence in quality, cost, delivery and most importantly, dramatic results to the organization’s bottom line.
This intensive Certified Lean Sigma Black Belt training is designed to develop experts with an in-depth understanding cum skills of both Lean & Six Sigma concepts, methods and tools that are necessary to achieve breakthrough improvement in critical to business processes. The program is specially structured to optimize learning and application through training, coaching and on-the-job project implementation.
The objective of this training program is to train the participants as Black Belts with advanced skills in analysing and improving processes using the Lean Sigma approach. Upon completion of this training, the participants will be able to:
- Work with management to set up process improvement projects.
- Lead project teams to execute improvement projects.
- Serve as mentors to improvement project teams lead by Green Belts.
- Disseminate and apply Lean Sigma principles, methodologies and tools in the organization.
Participants will be able to:
- Utilise the structured DMAIC methodology in solving functional problems with breakthrough results.
- Apply quantitative techniques to make effective fact-based decisions.
- Demonstrate the linkages between projects and desired business results.
- Lead subject matter experts to increase customer satisfaction levels & business efficiency.
- Manage & facilitate effective improvement project teams across the organization.
- Lead & manage cross-functional changes in their organization.
- Achieve breakthrough results through the application of creative & critical thinking to organizational problems.
- Communicate effectively to all levels in the organization.
BSI Neville Clarke is an IASSC ACCREDITED TRAINING ORGANIZATION for Certified Lean Sigma Green Belt and Certified Lean Sigma Black Belt courses. The only method to earn an IASSC certification is to successfully sit for and pass an official IASSC certification™ exam. We do / upon request, administer or provide access to IASSC Certification exams for no additional cost.
Phase 1: Define, Measure and Analyze
- Lean Sigma Overview
- Understanding Lean & Six Sigma, History of Lean & Six Sigma, Combined Lean & Six Sigma, Problem Solving Strategy, Deliverables of Lean Six Sigma Project, Roles & Responsibility, Defining a Process, DMAIC, Cost of Poor Quality, Lean Principles, 7 Elements of Waste
- Project Selection
- Business Case, Project Charter, Project Metrics, Financial Evaluation & Benefits, SIPOC, Voice of the Customer, Business and Employee
- Voice of Customer (VOC)
- Voice of the Customer, Kano Model, Critical to Quality Characteristics
- Value Stream Mapping (VSM)
- Current State Mapping, Future State Mapping, Value Stream Improvement Plan
- Process Mapping
- Flowchart, Cross Functional Mapping, Relationship Mapping
- Leading Effective Team
- Leadership Skills, Team Development Stages, RACI Chart, Team Effectiveness
- Data Collection Plan
- Types of Data, Data Selection, Operational Definition, Sampling Techniques & Uses
- Descriptive Statistics
- Basic Statistics, Descriptive Statistics, Graphical Analysis
- Graphical Tools
- Pareto Analysis, Histogram, Box Plot, Dot Plot, Run Chart, Scatter Diagram
- Measurement System Analysis (MSA)
- Precision & Accuracy, Bias & Linearity, Stability, Gage Repeatability & Reproducibility, Variable & Attribute MSA
- Process Capability Study
- Basic Six Sigma Capability Metrics (DPU, DPMO, FTY, RTY, Z-Score), Capability Analysis, Box-Cox Transformation, Attribute & Discrete Capability
- Cause and Effect Analysis
- Root Cause Analysis, Brainstorming, Cause & Effect / Fishbone Diagram, Affinity Diagram, Multi-voting, Nominal Group Technique, Selection Matrix, X-Y Diagram
- Variation Reduction Process
- Principles of Variation, Process Variation Reduction Steps
Phase 2: Analyze & Improve
- Failure Mode & Effect Analysis (FMEA)
- Developing FMEA, Risk Assessment
- Probability Distributions
- Normal Distribution, Student’s t Distribution, Binomial Distribution, Poisson Distribution, Weibull Distribution
- Sampling Distribution and Confidence Interval
- Inferential Statistics, Point & Intervl Estimate, Central Limit Theorem
- Multi-Vari Study
- Families of Variation, Multi-Vari Chart
- Hypothesis Testing
- Concept & Goal of Hypothesis Testing, Practical & Statistical Significance, Alpha & Beta Risk, Power & Sample Size, 1 & 2 Sample t-Tests, Paired t-Test, 1 & 2 Sample Variance Tests, 1 & 2 Proportion Tests
- Analysis of Variance (ANOVA)
- One-way ANOVA, Normality Test, Test for Equal Variances, Random & Fixed Effect, Crossed & Nested Design
- Non-Parametric Methods
- 1 Sample Sign, 1 Sample Wilcoxon, Mann-Whitney, Kruskal-Wallis, Mood’s Median, Friedman
- Chi-Square Test
- Contingency Table, Goodness-of-Fit Test
- 5S Workplace Organization*
- Sort, Straighten, Shine, Standardize, Self-Discipline
- Work Engineering Study
- Method Study, Work Measurement, Standard Time, Preferred Method
- Smooth Flow Manufacturing
- Flow Orientation, One-Piece Flow, Cell Manufacturing, Flow Pattern
Phase 3: Analyze & Improve
- Training Within Industry (TWI)
- Job Instruction, Job Method, Job Relation
- Correlation and Regression
- Correlation, Simple Linear Regression, Regression Equations, Coefficient of Determination
- Advanced Linear Regression
- Multiple Linear Regression, Residual Analysis, Confidence & Prediction Intervals, Discrete Predictors
- Nonlinear Regression
- Quadratic Model, Cubic Model, Nonlinear Regression
- Introduction to DOE
- Experiment Objectives, Experimental Methods
- Planning for Effective Experiment
- Experiment Design Considerations
- Full Factorial Design
- 2k Full Factorial Design, Balanced & Orthogonal Design, Factorial Plots, Center Point
- Fractional Factorial Design
- 2k-1 Fractional Factorial Design, Confounding Effects, Experimental Resolution
- Screening & Modelling of Experiments
- Screening for Significant Factors, Fit & Diagnose Model, Linear & Quadratic Mathematical Models
- Response Surface Methodology
- Central Composite Design, Box-Behnken Design, RSM Approach
- Additional DOE Techniques
- Gray Code Sequence, Fold-over Design, Taguchi Robust Design
Phase 4: Improve & Control
- Quick Changeover (SMED)
- Changeover Time, 6 Steps of Quick Changeover
- Pull Production with Kanban
- JIT Manufacturing, Push vs Pull, Kanban
- Load Leveling (Heijunka)
- Concept of Load Leveling, Loading, Sequencing
- Solutions Identification, Evaluation and Implementation Planning
- Solution Generation Techniques, Solution Evaluation Techniques, Cost Benefit Analysis, Implementation Planning, Risk Assessment
- Process Control & Standardization
- Elements of Control Plan, Elements of Response Plan, Documentation, Monitoring & Feedback
- Variable Control Charts
- Statistical Process Control, Concept of Stability, Data Collection, Subgroups, Impact of Variation, Frequency of Sampling, Control Methods, Control Chart Anatomy, Center Line & Control Limit Calculations, Xbar-R Chart, Xbar-S Chart, I-MR Chart
- Attribute Control Charts
- P Chart, NP Chart, C Chart, U Chart
- Advanced Control Charts
- Poka-Yoke (Mistake Proofing)
- Concept of Poka-Yoke, Poka-Yoke Devices
- Total Productive Maintenance (TPM)
- 8 Pillars of TPM, Overall Equipment Effectiveness
Note 1: The module on 5S Workplace Organization will be delivered through e-learning. Each candidate will be allocated with a secured password upon the commencement of the training to access for learning and assessment. This e-learning module must be completed before the next phase of training.
Note 2: MINITABTM software will be the official software used during the training.
This training is designed for organizational leaders that are assigned to carry out Lean Sigma projects, such as Managers, Section Managers, Principal/ Senior Engineers and Senior Officers.
Lean Sigma Black Belt Certification Requirements
Training (Certificate of Attendance)
- Completion of Lean Sigma Black Belt Training with a minimum attendance of 90% per phase.
IASSC Certified Lean Six Sigma Black Belt Exam*
The IASSC Certified Lean Six Sigma Black Belt (ICBB) Exam is a 4 hour 150 question proctored exam based on the IASSC Universally Accepted Lean Six Sigma Body of Knowledge for Black Belts. The Exam contains approximately 30 multiple-choice and true/false questions from each major section of the ILSSBOK for Black Belts.
In order to achieve this accredited designation of IASSC Certified Black Belt (ICBB) from the International Association for Six Sigma Certification candidates must sit for the IASSC Certified Lean Six Sigma Black Belt Exam and achieve a minimum score of 580 points out of a total potential of 750 points.
*The Certification Exam to be scheduled separately within 2 weeks after the 18 days of LSBB training
*In order to maintain the professional designation of IASSC Certified Black Belt (ICBB), candidates must sit for the IASSC Recertification Exam every 3 years
All BSI Neville Clarke tutors are full time consultants, auditors and trainers. The tutor assigned is always an experienced professional with practical application of the subject matter, who will be able to understand and meet the unique requirement of your industry.
18 days (training will be divided into 4 Phases; Phase 1, 2, 3 & 4), excluding the LSBB Certification Exam to be scheduled within 2 weeks after the training