LEAN SIX SIGMA MASTER BLACK BELT

Lean Management module:

• Understand the philosophy, tools and principles of Lean Management.
• Assess the production capacity, wastage of resources and delivery time of a production unit, a flow of activities or an organization.
• Draw up a process map based on field observations un order to describe and communicate the reality of operations.
• Analyze a process to locate and quantify bottlenecks, overcapacity, waste and malfunctions of all kinds.
• Make operations faster, more agile, efficient and reliable.
• Develop a performance management system bases on field indicators and problem-tracking routines.
• Conduct a flow and/or organizational efficiency problem-solving workshop based on the “Kaizen Event” approach

Six Sigma Yellow Belt module:

• Analyze the results of a customer satisfaction and expectations survey to identify the quality criteria to be improved.
• Assess the extent and cost of a quality problem.
• Determine the main root causes of a simple quality problem.
• Carry out a comparative assessment of different potential solutions.
• Develop a process performance management system.
• Conduct a DMAIC project to resolve a simple (“discernible”) quality problem.

Six Sigma Green Belt module:

• Determine the key quality metric to enhance in the company’s processes, based on an analysis of customer requirements.
• Define the operating parameters to be measured, how they are to be measured, and the sample of cases to be taken, to collect the data needed to carry out an analysis of non-quality factors.
• Approximately validate the reliability of the system for measuring the quality of the company’s products or services, to be able to collect data that sufficiently reflects the reality of operations.
• Determine certain non-quality factors using statistical analysis with a view to achieve a first step of improvement.
• Develop a process performance management system based on statistical quality control.
• Conduct a DMAIC project to resolve a complex (“indistinguishable”) quality problem.

Six Sigma Black Belt module:

• Rigorously validate the precision and accuracy of a quality measurement system to enable the collection of high-quality data.
• Determine whether the process quality indicator is governed by a normal probability distribution to choose the most appropriate inferential statistical analysis tools.
• Using hypothesis testing and linear regression analysis, determine finely the non-quality factors on which to act to achieve a high level of quality.
• Identify the range of tests to be conducted in a factorial design of experiments to assess the impact of process operating conditions on product quality.
• Determine the best operating conditions for a process by analyzing the results of a factorial design of experiments.

Six Sigma Master Black Belt module:

• Carry out a probabilistic capability study and check that a performance target has been achieved using specific hypothesis tests for all types of data and statistical distributions.
• Remove the indeterminacy about the influencing factors of a statistical problem by relying on an advanced use of hypothesis tests and sampling calculations for all types of data.
• Determine the optimal sampling strategy that maximize the effectiveness of a control chart

• Download the documentation

Days 1 and 2 – Lean Management Module

• History and positioning of Lean Management
• DMAIC method and Kaizen Event
• Process capacity: cycle time and Takt time
• Work-in-progress, inventory, waiting time, and Little’s law
• Value Stream Mapping (VSM)
• Rhythm diagrams
• Value-added analysis and waste elimination
• Process Cycle Efficiency and Overall Process Efficiency
• First Pass Yield and Rolled Throughput Yield
• Theory of constraints and line balancing
• Continuous flow
• Pull system and kanban
• Visual management, poka-yoke, 5S
• SMED
• Heijunka, dynamic capacity adjustment, and standardization
• Maximum acceptable work-in-progress (WIP max)
• Kata and Short Interval Management
• Toyota Way
• Complex flow analysis
• Failure Modes and Effects Analysis (FMEA)

Days 3 and 4 – Six Sigma Yellow Belt Module

• History and positioning of Lean Six Sigma
• Typology (LSSx.0) of problems and DMAIC projects
• DEFINE
• Project launch
• SIPOC
• The 3 Voices
• Critical To Satisfaction
• Kano Model
• Problem statement, objective statement, and project opportunity
• Project charter v1
• MAIC method for solving simple statistical problems

MEASURE

• Problem metric
• Measurement plan
• Validation of the measurement system: precision and accuracy (concordance analysis)
• Defect rate
• Project charter v2

ANALYZE

• Pareto analysis
• Five Whys
• Project charter v3

IMPROVE

• Solution research and selection
• Business Case
• Solution implementation
• Improvement validation

CONTROL

• Performance tracking dashboard
• Response plan

Days 5, 6, and 7 – Six Sigma Green Belt Module

MAIC method for solving complex statistical problems

MEASURE

• Basic statistics and data types
• Project Y and defect definition
• Measurement plan
• Validation of the measurement system: gauge R&R, linearity, and bias
• Sampling and data validation
• Process Voice Analysis
• Capability
• Project charter v2

ANALYZE

• Analysis process Y = f (X’s)
• Ishikawa diagram
• Introduction to inferential statistics (confidence interval concept)
• Study of influence on variation, central tendency, proportions, and covariance: contingency tables, graphical analysis (box plots and scatter plots), correlation coefficient, confidence interval analysis
• Hypothesis testing and regression analysis
• Introduction to hypothesis testing
• Normality test
• Influence on variation: equality of variances tests
• Influence on central tendency: ANOVA test, Mood’s median test
• Pearson correlation test, simple linear regression analysis
• Chi-square association test
• Project charter v3

IMPROVE

• Statistical validation of improvement

CONTROL

• Statistical process control
• Control Charts: I-MR, Xbar-R, Xbar-S, P and NP, U and C charts
• Response plan

Days 8, 9, and 10 – Six Sigma Black Belt Module

• Measurement system analysis
• Concordance analysis: Kappa and Kendall tests
• Gauge R&R: ANOVA method and measurement system resolution
• Linearity study (regression method) and bias test
• Hypothesis testing and regression analysis
• Introduction to hypothesis testing
• Normality test
• Influence on variation: equality of variances tests
• Influence on central tendency: ANOVA test, Mood’s median test, Kruskall-Wallis test
• Chi-square association test
• Pearson correlation test
• Simple and multiple linear regression analysis
• Design of experiments (DoE)
• 2-level factorial designs
• Experiment resolution
• Number of repetitions
• Experiment execution
• Analysis of main effects and interaction effects
• Pareto of effects
• Response surface
• Response optimizer

Days 11, 12, and 13 – Six Sigma Master Black Belt Module

• Probabilistic capability analysis
• Expected defect rate in normal, non-normal continuous, Poisson, and binomial distributions
• Data transformation (Box-Cox, Johnson)
• Hypothesis testing and regression analysis
• Test power and sample size
• 2-sample t-test, Mann-Whitney test
• 2-variance test, Friedman test
• 2-proportion test
• 2-sample Poisson test
• Hypothesis testing and regression analysis (continued)
• 1-sample t-test, 1-sample Sign test
• 1-standard deviation test
• 1-proportion test
• 1-sample Poisson test
• Logistic regression
• Multiple and general regression
• Statistical process control
• Control chart effectiveness
• Time-weighted control charts

Lean Six Sigma Deployment:

• Global governance
• Process management system
• Ambition and roadmap
• Lean Six Sigma organization
• Roles & responsibilities (Champion, Sponsor, Process Owner, Belts)
• Project selection and monitoring process
• Expected benefits

• Project managers/consultants (internal or external) in organization, quality, continuous improvement, or operational excellence
• Logistics managers
• Supply Chain Managers
• Production managers
• Operations Managers
• Quality managers
• Quality engineers
• Research & Development Engineers
  All sectors (industry and services).

• Inductive pedagogy
  • Experimentation with the Lean improvement method (Kaizen Event) through a role-playing game simulating a cross-functional business process (order reception, processing/production, invoicing, shipping).
  • Learning the DMAIC method through a case study used as a guiding thread throughout the training.
  • Learning to solve “indiscernible” problems using statistical tools in a service level improvement case study (paper flying machines) executed in class by participants.
  • Carrying out a design of experiments in class on a problem of optimizing the geometry of paper flying machines.
  • Determining the capability of a screw production process.
  • Determining the capability of a printing process.
• Groups of no more than 12 participants to promote interactivity, idea-sharing, and networking.
• Use of JASP, Statoscopex and Minitab statistical analysis softwares
• Provision of statistical calculators and analysis models in Excel.
• Training materials available in PDF version.
• Self-assessment and practice tests at the end of each module.

Lean Management and Six Sigma Master Black Belt certifications are awarded based on passing the Lean Management and Six Sigma Master Black Belt exams.

These exams validate the acquisition of Lean Management and Six Sigma Master Black Belt knowledge, in line with the LSSx.0 body of knowledge, which is necessary for developing the targeted skills. The exams include a mix of recall questions (e.g., definitions), execution tasks (e.g., calculations, tool selection), and application of acquired knowledge (e.g., conclusions based on results, decision-making in a given situation).

• Online exams, closed-book, with video monitoring from the candidate’s computer.
• Lean Management exam: 25 questions in 50 minutes.
• Six Sigma Master Black Belt exam: 55 questions in 110 minutes.
• Language: French or English.
• Exams must be taken within six months of the training.
• The candidate can freely schedule the exams at their convenience.
• Pass criteria: score ≥ 60%.
• One retake allowed in case of failure.
• It is possible to retake the exam after a second failure by purchasing a new exam.