Six Sigma Black Belt Training CBT Module Course Outline (Week 1 and 2)

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Week 1

A. The Environment for Six Sigma Projects - Setting the Stage

    1. The Hidden Factory
    2. The Quality Lever
    3. The Demanding Nature of Customers
    4. The Nature of Process Variation

B. The DMAIC Process

    1. Six Sigma Project Selection
    2. The Process, Phases and Steps of DMAIC
    3. DMAIC Steps 1 and 2

C. The Voice of the Customer

    1. Overview of the Quality Function Deployment (QFD) Phases
    2. QFD’s Phase 0 - The Voice of the Customer

        a. The Klein model of customers’ perceptions of quality
        b. Techniques for gathering and analyzing customer data
        c. Sources of customer data
        d. Guidelines for creating and asking better survey or interview questions
        e. Using the QFD matrix to translate CCRs into CTQs

D. Basic Tools of Phases I and II

    1. SIPOC
    2. Team Charter
    3. Sampling
    4. Checksheets

E. Introduction to Team Building (Optional)

    1. Benefits
    2. Integrated Teams
    3. Development Stages
    4. Team Dynamics
    5. Product Meeting Guidelines
    6. Team Roles
    7. Meeting Skills
    8. Giving and Receiving Feedback

F. Descriptive Statistics

    1. Charting Data Over Time
    2. Summary Data Patterns and Histograms
    3. Measures of Central Tendency and Dispersion
    4. The Normal Distribution Curve
    5. Process Control vs. Process Capability
    6. Boxplots
    7. Point and Interval Estimates
    8. Confidence Intervals, with Decision Tree (Optional)

        a. Z Distribution on Means
        b. t Distribution on Means
        c. c2 Distribution on Variation

    9. Tests for Normality
    10. Typical 6 sigma Performance Metrics (p. 186-193)

        a. Defect - Based
        b. Capability - Based
        c. Sigmas

G. Measurement Variation Analysis

    1. Repeatability
    2. Reproducibility
    3. Procedure for Conducting
    4. Interpreting Results and Follow-up Actions
    5. Accuracy, Stability, Linearity

H. The Steps and Basic Tools of Phase III

    1. The Basic Tools for Data Collection

        a. Tally sheets, Check sheets
        b. Histograms & Pareto

    2. The Basic Tools for Data Analysis

        a. Teaming/Brainstorming
        b. The 5 Why? 's
        c. Root Cause Analysis
        d. Cause & Effect Diagram or Fishbone Diagram 
        e. Scatter Diagram
        f. Charting Data over Time
        g. Multi-Vari Charts
        h. Process Mapping
        i. Statistical Testing
        j. Design of Experiments

Week 2

I. Process Mapping

1. The Basics of Process Mapping
2. Creating the As-Is Process Map
3. Analyzing the As-Is Process Map
   1. Value-Added Analysis
   2. Streamlining
   3. Reduction of Cycle Time, Distance Traveled, Number of Steps
   4. Identification of Breakdown Opportunities
4. Creating the Should-Be Process Map
5. The Process Mapping Scorecard

J. Statistical Population Tests

1. Basic Concepts and Terms
2. Statistical Risks
3. One- and Two-Tail Tests
4. Inference Test Decision Trees
5. Z Test on 2 Means
6. t Tests on 2 Means
7. χ² Test on 2 Variances 
8. F test on 2 Variances
9. χ² Goodness of Fit Test 
10. Tests on Multiple (>= 3) Means and Variances
    1. ANOVA
    2. ANOM
    3. Bartlett's
11. Tests on Proportions
12. Determining Sample Size
13. Non-Parametric Tests
14. Examples and Exercises

K. Introduction to Design of Experiments

    1. Basic Experimental Design and Analysis

1. Orthogonal Arrays and Fractional Factorials
2. Main Effects and Interactions
3. Level Averages and Response Graphs
4. Confounding
5. Mixed-Level Designs

    2. Intermediate Design and Analysis

1. Other Design Considerations (Blocking, Replications, Randomization, Centerpoints, etc.) 
2. 2-way and 3-way Designs
3. Analysis of Variance (ANOVA)
4. Signal-to-Noise Ratios (Static)
5. Parameter Design and Robustness
6. Variation Reduction and Centering of the Mean
7. Control and Tuning Factors
8. The Dynamic Case Signal-to-Noise Ratios
9. Introduction to Mixture Designs
10. Application of the Quality Loss Function in Tolerance Design

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