Lean Six Sigma – Black Belt

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Lean Six Sigma – Black Belt (duration 77 hours)

Overview

Interest in Lean Six Sigma has been growing steadily over the past few years. This advanced course introduces and deepens the fundamental concepts of the Lean Six Sigma philosophy and DMAIC methodology, and enables participants to understand and use the concepts, principles and tools at a Black Belt level.

The training supports active participation in your organization's Operational Excellence program. Participants see how a lack of quality can affect the organization, learn the meaning of Lean Six Sigma and explore the essential elements of its approach.

The Lean Six Sigma – Black Belt program provides a clear, structured framework oriented towards customer satisfaction, expense reduction, improved performance and higher quality. Because we believe in “training in action”, the course integrates a practical kaizen simulation so that participants can experience continuous improvement and waste elimination in practice.

Upon completion, participants will have a thorough understanding of Lean Six Sigma, will be able to identify processes requiring improvement and lead complex improvement projects. They will know how to respond to the Six Sigma challenge, develop a culture focused on its use and act as catalysts for change.

Objectives

Our Lean Six Sigma – Black Belt training approach is distinguished by the following objectives:

• Increase customer satisfaction.
• Increase the sense of belonging of both customers and employees.
• Improve the quality of services and/or products offered by the organization.
• Optimize current processes and create a culture of continuous improvement.
• Prepare participants for the internationally recognized ASQ Lean Six Sigma Black Belt certification exam.

The intervention approach integrates project management, benefits realization and change management practices, encouraging end-to-end process optimization based on recurring business issues. Interventions aim not only to achieve expected benefits, but also to develop a culture of continuous improvement.

Our work methods are reinforced by the following principles:

• Favour the Define – Measure – Analyze – Innovate (Improve) – Control (DMAIC) approach for its simplicity and rigor.
• Encourage involvement of business experts in problem analysis and solution development.
• Promote client autonomy through systematic knowledge transfer.
• Adapt DMAIC activity planning to the operational context of the teams.
• Apply “training in action”, integrating a practical simulation workshop.

Learning outcomes

Upon completion of the Lean Six Sigma – Black Belt training, participants will be able to:

• Increase the speed of operations and reduce non-value-added activities.
• Identify customer needs and deliver the required service, regardless of sector.
• Improve operational efficiency and increase the performance and competitiveness of the organization.
• Understand and apply Lean and Six Sigma concepts in their work environment and to continuous improvement projects.
• Explain and use the concepts, principles and tools of Lean and Six Sigma and the DMAIC methodology.
• Coach Yellow and Green Belts on projects and act as a reference point.
• Apply a clear and simple framework oriented towards customer satisfaction, reduced costs, higher performance and superior quality.

Target audience

This course is intended for anyone who needs to understand and apply Lean Six Sigma concepts in their work environment and who will be responsible for continuous improvement projects, reducing non-value-added activities and increasing process performance while improving the customer experience. It also prepares participants to sit an internationally recognized LSS Black Belt certification exam.

Course content

The training consists of nine modules. The reference manual is based on the ASQ “Body of Knowledge”. Training days alternate theoretical learning and practical application. A kaizen simulation workshop is integrated to let participants “live” continuous improvement and waste elimination. Case studies and sample ASQ exam questions are used to practice tools and confirm mastery.

• Module 1 – Deployment in the company
  • Company vision and leadership.
• Module 2 – Organizational process management and measurement
  • Impact on stakeholders, project follow-up.
• Module 3 – Project management
  • Project definition, team leadership, team dynamics and performance, change agent role, management and planning tools.
• Module 4 – Team management
  • Training, facilitation, team dynamics, time management, decision-making tools, performance evaluation and recognition.
• Module 5 – Lean Six Sigma methodology – Define
  • Voice of the customer, critical-to-quality characteristics, project definition and FIPEC-SIPOC, project control.
• Module 6 – Lean Six Sigma methodology – Measure
  • Process characteristics, data collection, measurement systems, descriptive statistics, process capability, and tools such as brainstorming, cause-and-effect diagrams and quality function deployment.
• Module 7 – Lean Six Sigma methodology – Analyze
  • Measuring and modelling relationships between variables, identifying factors to improve, failure analysis, value stream mapping, natural and assignable variation, additional analysis methods (e.g. whisker and interrelationship charts), probability and statistics, design of experiments, design for Six Sigma, ANOVA and regression, parametric and non-parametric distributions.
• Module 8 – Lean Six Sigma methodology – Innovate (Improve)
  • Determination and selection of solutions, improvement tools and methods, scenario evaluation, waste elimination, cycle time reduction, cause-and-effect diagrams and 5 Whys, kaizen, 5S and visual controls, Poka-Yoke, theory of constraints, piloting and implementation, risk analysis and mitigation.
• Module 9 – Lean Six Sigma methodology – Control
  • Statistical process control, other control tools, implementation and sustaining of controls, design for Six Sigma, robust design and signal-to-noise ratio.

Procedure

The training takes place over approximately six months and typically includes:

• 66 hours of instructor-led training.
• 1.5 hours for the exam.
• 1.5 hours for in-class review of the exam.
• 8 hours of group coaching and simulation workshop.

Optionally, participants can add 10 hours of individual coaching to support a real DMAIC project in their organization.