Black Belt Lean Six Sigma in English Présentiel

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
• 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

Lean Management Module:

• Understand the philosophy, tools, and principles of Lean Management
• Evaluate production capacity, resource losses, and delivery times of a production unit, an activity flow, or an organization.
• Analyze a process to locate and quantify dysfunctions of all kinds.
• Establish a process map based on field observations.
• Make operations faster, more agile, leaner, and more reliable.
• Develop a performance management system based on field indicators and problem tracking routines.
• Conduct a workshop for solving flow problems and/or organizational efficiency using the Kaizen Event approach.

Six Sigma Yellow Belt Module:

• Analyze the results of a satisfaction survey and customer expectations to identify the quality criterion to improve.
• Assess the magnitude and cost of a quality issue.
• Determine the main root causes of a simple quality problem.
• Conduct a comparative assessment of different potential solutions.
• Develop a performance management system for processes.
• Lead a DMAIC project for solving simple quality problems.

Six Sigma Green Belt Module:

• Define the quality indicator to improve within the company's processes based on an analysis of customer requirements.
• Define the operational parameters to measure, how to measure them, as well as the sample cases to collect data necessary for analyzing non-quality factors.
• Aproximately validate the reliability of the quality measurement system for the company's products or services to ensure that data collected accurately reflects operational reality.
• Determine certain non-quality factors using statistical analysis in order to achieve an initial level of improvement.
• Develop a performance management system for processes based on statistical quality control.
• Lead a DMAIC project for solving complex quality problems.

Six Sigma Black Belt Module:

• Rigorously validate the accuracy and precision of a quality measurement system to enable high-quality data collection.
• Determine if the process quality indicator follows a normal probability distribution in order to choose the most appropriate inferential statistical analysis tools.
• Carefully determine through hypothesis testing and linear regression analysis which non-quality factors to target in order to achieve high-quality levels.
• Specify different tests to conduct in a factorial experiment plan to understand how operating conditions affect produced quality.
• Determine the best operating conditions for a process by analyzing results from a factorial experiment plan.

All sectors (industry and services)

• Project managers / consultants (internal or external) in organization, quality, continuous improvement or operational excellenceLogistics managers
• Supply Chain Managers
• Production managers
• Operations Managers
• Quality managers
• Research & Development Engineers
• Quality Engineers

• Inductive pedagogy
  – Experimentation of 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 business case study serving as a guiding thread throughout the training.
  – Learning the "indiscernible" problem-solving method and utilizing statistical tools on a service level improvement case (paper flying machines) executed in class by participants.
  – Conducting an experimental plan in class on an optimization problem of the geometry of paper flying machines.
  – Determining the capability of a screw production process.
  – Determining the capability of a printing process.
• Groups of a maximum of 12 people facilitated to promote interactivity, sharing ideas and experiences, and developing their professional network.

• Use of statistical analysis software JASP, Statoscopex and Minitab.
• Provision of statistical calculators and analysis models in Excel.
• Training materials available in PDF versions.
• Self-assessment and training tests at the end of each module.

Lean Management and Six Sigma Black Belt Certifications obtained based on the successful completion of the Lean Management and Six Sigma Black Belt exams.

These exams validate the acquisition of knowledge in Lean Management and Six Sigma Black Belt according to the LSSx.0 body of knowledge, which is necessary for developing the targeted skills. It includes a mix of recall questions (e.g., definitions), execution (e.g., calculations, tool selection), and application of knowledge (e.g., drawing conclusions based on results, making decisions in a given situation).

• Online exams, closed book under video surveillance from the candidate's computer;
  • Lean Management Exam: 25 questions in 50 minutes
  • Six Sigma Black Belt Exam: 45 questions in 90 minutes
• Language: French or English.
• Deadline: exams must be taken within 6 months after training
• Mode: the candidate freely schedules their exams at a date and time that suits them.
• Passing criterion: Result ≥ 60%
• A retake is allowed in case of failure.
• It is possible to retake the exam in case of a second failure by purchasing a new exam.

• Lean Management in English
• Module Yellow Belt in English
• Module Green Belt in English
• Module Black Belt in English