Black Belt Body of Knowledge (1)
- Introduction
- Six sigma history and terminology
- Define-Measure-Analyze-Improve-Control (DMAIC) methodology
- Processes, inputs and outputs
- Six sigma roles and responsibilities
- Theory of constraints
- Introduction to lean
- Integration of six sigma and lean
- Manufacturing and service six sigma and lean applications- examples of projects
- Project selection
- Project selection criteria
- Internal metrics: parts per million, defects per million opportunities, rolled through quality
- Voice of the customer: SIPOC, affinity diagrams, kano diagrams, critical to satisfaction
- Detailed process map
- Lean enterprise
- Introduction to lean– lean tools and eight wastes
- Value stream mapping
- 5 S
- Quick changeover
- Total Productive Maintenance
- Team building
- Roles and responsibilities
- Four stages: storming, forming, norming and performing
- Ingredients for successful teams
- Communication and feedback
- Basic Statistics
- Terms: Sample, population, distribution, mean, median, mode, range, standard deviation
- Descriptive statistics
- Normal and non-normal data, Anderson-Darling test
- Graphic methods: Histograms, pareto charts, scatter diagrams
- Variable and attribute data
- Run charts and control charts: I-MR, x-bar and R, P, NP, C, and U
- Special and common cause variation
- Control chart analysis
- MINITAB exercises
- Define Phase
- D1- Select an output characteristic
- D2- Define the performance standard
- D3- Describe the process
- Detailed process mapping
- Project charter, problem statements
- Project scope, goals, objectives, and performance measures
- Measure Phase
- M1- Validate the measuring system
- Attribute agreement analysis and variable gage R & R
- MINITAB exercises
- M2- Establish current process capability
- Measurement methods
- Data collection, sampling methods, types of data
- Process performance verses specifications
- Attribute and variable process capability
- MINITAB exercises
- M3- Determine project objectives
- M1- Validate the measuring system
- Analyze Phase
- A1 and A2- Identifying and screening potential causes
- Root cause analysis
- Brainstorming, list reduction, five why
- Cause and effect diagrams
- Cause and effect matrix, family of variation, and potential “X†matrix
- Process failure and effects analysis (FMEA)
- Hypothesis testing
- Terminology: significance level, power, resolution, alpha and beta error
- 1-proportion, 2-proportion, Chi square
- 1-sample t, 2-sample t, ANOVA
- Paired t
- MINITAB exercises
- A3- Determining the f(x)
- One factor at a time experiment
- Correlation
- Regression
- Design of experiments
- Full factorial design
- Fractional factorial
- MINITAB exercises
- A1 and A2- Identifying and screening potential causes
- Improve Phase
- I1- Develop Solutions(s)
- Solution matrices
- Managing change
- I2- Re-evaluate the measuring system
- I3- Implement and establish final capability
- Pilot study
- I1- Develop Solutions(s)
- Control Phase
- C1- Implement process controls
- Control plan
- Mistake proofing
- Internal audits
- Lessons learned
- Ongoing evaluation
- C1- Implement process controls