Course overview
TEC Transnational’s Lean Six Sigma Black Belt Training Program consists of a series of 2-day tutor-led training sessions following the D-M-A-I-C cycle - delivered on a monthly basis. Each session contains exercises and ‘homework’ sessions to ensure that the principles and practices are fully understood. In parallel, students undertake individual ‘break-through’ projects to ensure that their newly acquired skills are put to use immediately to the benefit of their organizations – “achieving excellence through accelerated learning”!
Each of the tutor-led courses is highly interactive and uses worked examples and group exercises to illustrate the principles, methodologies and statistics involved. TEC use and recommend Minitab statistical software.
Course details
The practical training is delivered as five 2-day tutor-led sessions scheduled over five to six months to maximize the benefits and minimize any disruption to routine work activities.
The break through project activities commence after the Recognise/Define step and serve to support and accelerate the progress of learning for the individuals involved and maximize their organization’s return on its investment. Each training session contains ‘hands-on’ exercises focused on the selected topics so that learning and competency can be assessed and any individual ’skills gaps’ can be recognised and addressed immediately.
The program syllabus includes the following topics –
Recognise/Define:
Introduction to basic statistics
Developing the business case
Identifying key stakeholders
House of quality
Stakeholder analysis
Voice of the customer
Critical to ‘X’ (CTX)
Verifying CTXs
Identify and segment
High level process map
Project charter
Project plan
Applicable lean manufacturing topics
Measure:
Understanding variability
Measurement basics
Measurement process and plan
Selecting measures
Data definition and sources
Sampling techniques
Measuring yield and capability
Implementing the measure plan
The ‘hidden factory’
Applicable lean manufacturing topics
Analyse:
Working with different data ‘types’
Continuous
Count
Attribute
Understanding probability distributions
Binomial
Poisson
Exponential
Normal
Understanding how probability distribution models are created
Major distributions
Discrete
Continuous
Visualizing probability distributions
Matching a probability distribution to a particular context
Understanding the ‘flow’ o the Analyse Step
Refine problem definition – look at the source (Genba)
Process mapping, analysis and control
Looking for trends and patterns with basic statistical analysis
Mean, Median, Mode
Regression and correlation analysis
Graphical techniques for data display
Introduction to the comparison of processes
Understanding population and samples
parameters and ‘statistics’
central limit theorem
probabilities
Fundamentals of hypothesis testing
Hypothesis testing for AVERAGES
central tendency
mean, median and mode
z-tests
t-tests (1-sample & 2-sample)
One-way ANOVA
Hypothesis testing for STANDARD DEVIATIONS
Measuring and confirming process improvement
special causes
common causes
Applicable lean manufacturing topics
Improve:
Brain storming techniques
Understand the process approach
Lean principles and practices
Optimising flow
Rapid changeover (SMED)
Introduction to Kanban
Visual management techniques
Developing solution options
Choosing between possible solutions
Facilitating kaizen events and improvements teams
FMEA and FTA (risk analysis)
Project implementation planning
Applicable lean manufacturing topics
Control:
Documentation - the 'KISS principle'
Poke Yoke (mistake proofing)
Statistics process control (SPC)
Process management
Team Charts and ‘Storyboards’
Writing a Six Sigma Project
Applicable lean manufacturing topics
The individual ‘break-through’ projects are agreed with a senior member of the organization’s staff, which are documented in a Project Charter.
Who should attend
Participants are typically Team Leaders, Continuous Improvement Champions and SC21 Change Agents. Some organizations prefer to choose a group of 4 – 10 participants and have the courses delivered on site.
Every participant elects to undertake a major 'break-through' project which they work on over 3- to 6-month period. Consequently their newly acquired project management and continual improvement skills can be put to work immediately to the benefit of their organization.
TEC Transnational have chosen Minitab as the preferred applications software for their Six Sigma Training Program.
Deliverables & benefits
Individual benefits & Qualifications
Manufacturing industries are continually searching for ‘real problem solvers’ which provides an opportunity for individuals to gain the credentials of a Six Sigma ‘practitioner’
The skills you will learn enable you to become more proficient at managing ‘break-through’ projects that deliver tangible gains on the bottom line
Development of your leadership skills and added-value to your CV and LinkedIn profile
Individuals who attend all of the tutor-led training sessions and complete all of the course exercises and 'homework' will receive a Green Belt qualification
Individuals, who in addition, complete and submit an acceptable break through project will be awarded a Six Sigma Black Belt qualification.
Organization benefits
Six Sigma enables organizations to improve their processes, making them more capable of delivering what the customer wants right-first-time, on-time and at cost. Combining the principles and practices of Lean Manufacturing serves to boost the ‘break-through’ improvements, and ensure that best practices are fully integrated. The resulting benefits to the organization can be substantial, and organizations will achieve –
greater productivity
higher throughput with the same resources
improved quality
reduced cycle times
less ‘fire fighting’
smoother operation – less hassle
reduced operating costs
TEC Transnational’s 'Master Trainers' have extensive experience deploying both Lean Manufacturing and Six Sigma in the aviation, defence, automotive, motorsport and rail sectors. We work with individual companies and supply chain groups.