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ISL-Certified Lean Six Sigma Black Belt

(Free International Certification


from IQF, USA)
Lean and Six Sigma have evolved in Toyota,
Japan and Motorola, USA respectively.
Lean has a reputation of making the
organization to drive cost reduction through
creating an organization wide war on waste.
Lean makes the organization competitive in
the long-term. On the other hand, Six Sigma
proved itself as the most effective problem
solving approach and delivers breakthrough
results in the short-term.
An organization can gain both in short-term
and long-term by combining the Lean as
well as Six Sigma approaches. Lean Sigma
program combines the best of American and
Japanese quality management practices.
ISL-certified Lean Six Sigma Black Belts
are at the core of the Lean Six Sigma
implementation. Black Belt is an
individual who has developed a synergistic
proficiency between his or her technical
discipline and the Lean and Six Sigma
strategies, methodology and tools. Black
Belt skills are not only required for people
working in Quality department as they
improve the productivity of people in all
other functional departments.
Lean efforts are not limited to
manufacturing; a lean mindset applies to any
process. Lean techniques can be used to
reduce waste and add value to processes in
the office, in maintenance, and even in sales
and R&D. In some cases, the impact of a
lean approach in the office can be even more
dramatic than in manufacturing processes.

Silver certification is focused on application


of lean principles and tools atvalue stream
level, which is referred as integrative lean
which involves integration of lean activities
and organizational restructuring to transform
the value stream and sustain the same. You
should also have the ability to mentor and
coach others on both tactical and integrative
Lean.
Black Belts are also trained in soft skills.
The combination of process analysis,
statistical and soft skills makes the Black
Belts ideal candidates to act as change
agents. Black Belt slowly and steadily
change the way people think and act in the
day-to-day work. Often this is referred
cultural change.

Learning Objectives

To understand the philosophy of six


sigma
To learn DMAIC methodology and
statistical tools application
To learn DFSS methodology and
advanced tools application
To be able to leadand coachBlack
Belt projects
To understand the basic concepts,
tools and practices of Lean
To understand the organizational
cultural aspects of Lean
To be able to apply VSM, SMED
and hoshin planning
To be able to explain and use lean
accounting practices
To be able to lead and coach A3
problem solving teams
To be able to help Champion is
selecting Right projects

Methodology
This training and certification is delivered
completely
online.
The
Learning
Management System (LMS) provides
following elements:

Multimedia lecture (Audio with


automatic slide transition)
Quiz, with answers and explanation
to wrong questions.
Discussion forum for engaging in
dialogue with other participants.
Step-by-Step-project guidance

Course Content
The course is based on Body-of-Knowledge
of IQF, USA and SME, USA:
Six Sigma Concept & Philosophy
o Six Sigma Concepts and
Philosophy
o Six Sigma Deployment
o Metrics: DPU,DPMO, RTY
o Champion, Black Belt and Green
Belts
o Selecting Projects
Define and Measure Stage
o Define Stage: Creating Project
Charter, Identifying Customers &
Their Needs and Requirements,
Creating SIPOC
o Measure
Stage:
Identifying
CTQs,
Selecting
Sampling
Strategy and Collect the data,
Establish
the
Baseline
Performance
o Basic Statistics: Concept of
Variation, Data Types; Normal,
Exponential, Binomial, Poisson
distributions, Measures of central
tendency - Mean, Median, Mode,
Measures of Dispersion - Range,
Standard deviation, Variance,
Central Limit Theorem

o Visualization
Techniques:
Process
Mapping,
Quality
Function Deployment (QFD)
o Measurement System Analysis:
Types of errors in Measurement
System, R&R for Variable
measurement, R&R for Visual
Inspection
Analyze Stage
o Analysis Stage : Sources of
variation, Identifying root cause
and Validation
o Data Analysis: common and
special causes of variation,
Control charts, Xbar and Range
Chart, Individual and Moving
Range Chart, Histogram, p-chart,
c-chart, Pareto analysis, Precontrol charts
o Process Capability: Cp, Cpk, Pp,
Ppk
o Cause Analysis: Cause and
Effectdiagram,Why-Why
analysis.
o Diagnostic Techniques: MultiVari chart, Paired comparison
Improve Stage
o Improving Stage: Generating
Potential Solutions, Select the
Best One, Developing MistakeProof
Measures,
Process
Optimization, Validating the
Results
o Advanced Statistics: Sampling
distribution,
Estimation,
Hypothesis Testing, ANOVA,
Correlation and Regression
o Design of Experiments (DoE):
Fractional Factorial designs, Full
Factorial designs.
Control Stage
o Control Stage: Defining the
Process
Control
System,
Modifying the Documentation
System, Conducting Training,

Institute the Process Audit


System, Quantifying the Gains
o Control Plans
o Failure Modes and Effects
Analysis (FMEA).
o Team Working
Origin and Philosophy
o Mass production vs Lean
o Muda, Mura, Muri
o Seven Types of Wastes
o Value-added Activity
o Lean Manufacturing House
o Lean thinking Model
Operational Stability
o Indicators of Stability
o Strategies for stability
o Standards and Visual Control
o 5S,
Red-tagging,
Spaghetti
diagram
o TPM, Six Big losses, quasiproblems
Standard Work
o Standardization benefits, prerequisites, people focus
o 3 elements of standard work
o Takt time, work sequence, inprocess stock
o Charts for standardized work
production
capacity
chart,
standardized work combination
table, standardized work analysis
chart, job element sheet
o Individual and overall efficiency,
manpower reduction
o kaizen and layouts
Just-in-Time
o Littles law
o Push system, large lot production
o Pull system, basics of JIT
o Continuous Process Flow, one
piece flow

o Push
scheduling,
Kanban,
Pacemaker process,
o Six Kanban Rules, types of
kanbans
o Conveyance, Hejunka, Changes
in demand
o Types of pull Type A, B and C
Jidoka
o Autonomation
o Zero-quality control
o Types of Inspection Judgment,
Informative, Source, Vertical,
horizontal
o Three aspects of Poka yoke
Actions, Paths and Methods of
detection
o Andon
Involvement
o Goal involvement
o Types of Kaizen teams Kaizen
Circle
Activities,
Practical
Kaizen Training
o Roles,
Responsibilities
of
members, facilitators, managers
etc.
o Kaizen Leadership
o Suggestion scheme
measurement, motivation
o Problem Solving
A3 Problem Solving
o Introduction
o Problem Situation
o Target
o Theme
o Cause Analysis
o Countermeasures
o Implementation
o Follow up

Six Sigma Leadership


o Enterprise View
o DMAIC Plus Model
o Toolkit for Six Sigma Leaders
o Risk Analysis
o Quality Gurus
Advanced Data Analysis
o Understanding Variation and
Causes
o Strategies to Reduce Variation
o Understanding SPC
o SPC for Special Cases
o Advanced Statistical Concepts
Optimization and Robust Design
o Factorial Designs
o Fractional Factorial Designs
o Taguchi Methods, S/N Ratios
o Planning
and
Organizing
Experiments
o Advanced DOE
Design for Six Sigma
o Understanding DFSS
o Voice of the Customer & QFD
o Design of Manufacturability
o System and Design FMEAs
o Risk Management
o Axiomatic Design
o TRIZ and Creativity
Change Management
o Managing Cultural Change
o Managing Teams
o Facilitation Process and Tools
o Team
Dynamics
and
Performance
o Project Management
o Knowledge Management
o Management & Planning Tools
Toyota Way
o Understanding Toyota Way
o Constancy and Grow Leaders
o Develop People &Teams
o Long-term
Approach
with
Partners and Suppliers

o GenchiGenbutsu,
Decision
Making and Lean Organization
Value Stream Mapping
o Basic Concepts of VSM
o Documenting Production or
Process Flow
o Adding Facts to the Map
o Capturing Travel Distances
o Capturing Communication Flow
o Creating Future State Map
SMED and SBCE
o Single Minute Exchange of Dies
(SMED)
History of SMED
Conceptual Stages
Steps for SMED
Practical Techniques
o Lean Product
Development
(SBCE)
Basics
of
Set-based
Approach
Principles of Set-Based
Concurrent Engineering
(SBCE)
HoshinKanri
o Understanding HoshinKanri
o Implementing HoshinKanri
o X-matrix
o A3-X
o Cathball
Total Productive Maintenance (TPM)
o Understanding TPM
o Six Big Losses
o Autonomous Maintenance
o Education, Health and Safety
o Quality Improvement

Lean Accounting
o Lean Accounting Basics
o Lean Performance Measurement
o Cell Performance Measurement
o Value Stream Measurement

IQF BoK Basic Topics


o Distributions
o Statistical Inference & ANOVA
o Measurement Assurance
o SPC
o Process Capability
o One-Way ANOVA

IQF BoK Advanced Topics


o Advanced Distributions
o Advanced Statistical Inference &
ANOVA
o Advanced-Measurement
Assurance
o Regression
o Multi-Factor ANOVA
o Project Value
o Project Management

Complete two Lean Six Sigma


Projects

E-Dialogue
E-Dialogue is specially designed to improve
interaction between you and our mentors
and as well with other students. It uses a
structured approach for
reading/posting/replying messages.

Certification Criteria
IQF- Lean Six Sigma Black Belt
certification is awarded on completion of the
following:

Complete all learning modules


Score 60% or more in quiz at the end
of each learning module
Quality IQF-Lean Six Sigma Black
Belt exam
o Score 60% or more in
Fundamentals section
o Score 50% or more in
Applications section

E-QUIZ
The e-Quiz is an interesting tool to help you
in testing your knowledge. You can test your
knowledge at each module. You can also
check your preparedness to IQF and ASQ,

USA Exams. The module wise, topic wise


details evaluation report is generated
instantly. The questions are generated
randomly and for each wrong answer, right
answers along with comments are also
displayed instantly

WHO CAN DO THIS COURSE

E-FACILITATOR
The e-Facilitator is an innovative tool to
help you in implementing the lean six sigma
DMAIC project. Experienced Black Belts
and Master Black Belts will review your
project at every stage and give guidance.
You can interact with BB/MBB through this
tool.

This training and certification is designed


for Manufacturing, Services, and Software,
BPO and call centers. This course is useful
for people working in all functions - HR,
Operations,
Finance,
Logistics,
etc.
REGISTRATION
Register online at www.isl.co.in and pay Fee
Rs 68,540/ (for students in India) and
1,17,810/- (for students outside India)
through Credit Card, bank transfer, Demand
Draft or Cheque (in favour of Institute of
Sigma Learning Pvt. Ltd, Hyderabad).
You will receive the course material within
10 working days.

FAQ
Who gives the Lean Six Sigma Black Belt
Certificate?
ISL Lean Six Sigma Black Belt is prepared
for International Quality Federation (IQF),
USA certification. IQF Lean Six Sigma
Black Belts are required to pass the IQF
exam to quality for the award of IQF
Certificate.
How do these certificates recognized?
Currently there are two third party agencies
from USA, who are offering the Lean Six
Sigma Black Belt certification, namely,
American Society for Quality (ASQ) and
International Quality Federation (IQF). They
conduct exam and certify the qualified.

I am NOT from six sigma Company, how


can I do projects?
ISL is not looking for any certificate from
your company. The Mentors will be
interested in checking your skills in applying
lean six sigma methodology and tools and
give you feedback. This is part of the
learning process.
ABOUT ISL
Institute of Sigma Learning Pvt. Ltd. (ISL)
is started with a vision of providing these
courses at a reasonable cost. ISL has the
experience of training more than 300 Black
Belts in India and abroad. ISL is
representing
International
Quality
Federation (IQF), USA and authorized to
issue certificates in India. ISL is first to
publish books on six sigma and also first to
launch distance learning courses in six

sigma. ISL is continually developing


Microsoft Excel based templates to help the
Black Belts and Green Belts in the data
analysis without the need to use expensive
statistical softwares such as MINITAB,
SPSS etc. Further ISL is first to introduce
innovative web-based tools for accelerating
self learning. Web-based tools are
e-Dialogue, e-Quiz and e-Facilitator