Black Belt Course Overview

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Instructor Introductions
Instructors will introduce themselves

Shaw Industries Group, Inc. Internal Use Only

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Student Introductions
Students will introduce themselves
Name Division/plant/location Years experience Hobby/interest Project problem statement Expectations Statistical baseline and Lean baseline
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Statistical Baseline
Where are we as a class our personal knowledge:
1 I have never used statistical methods 3 I use some data occasionally 5 I use data frequently 7 I almost always use data and know what to do with it 9 I should be teaching this stuff
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Lean Baseline
Where are we as a class our personal knowledge:
1 I have never used lean tools/techniques 3 I use lean tools occasionally 5 I use lean tools frequently 7 I almost always use lean, regardless of the process/environment 9 I should be teaching this stuff
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Expectations
Completed project charter Completed Steps 1-3 of the Lean Six Sigma Roadmap Completed your pre-work assignments Will actively participate in class Will come to class prepared Will follow the Code of Conduct
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Code of Conduct
Cell phones and pagers turned off

Start/keep/end on time
Frequent breaks to stay fresh Two-way communication required ask questions as we go Please share experiences or real data that relate to the topic Lots of team activities please participate fully Listen as an ally How can I use this tool in my situation? Parking Lot used to capture issues/concerns to be discussed as time situation permits Benefits and Concerns (Bs and Cs) at the end of each day
Any others?
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How Do We Learn?
Teaching Techniques
Presentation Reading Audio-Visual Demonstration

Retention Rate
5% 10% 20% 30%

Characteristics
Time Pressured Content Focused Spray and Pray

Discussion Group
Practice with Feedback

50%
75%

Teach Others/Immediate Use80%

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Learner Focused Interactive Time-Consuming

Our Environment
Teaching Techniques
Pre-Work Classroom concept lecture/discussion Classroom applications Homework assignments Project application for immediate use
Presentation Reading Audio-Visual

Retention Rate
5% 10% 20%

Demonstration
Discussion Group Practice with Feedback

30%
50% 75%

Teach Others/Immediate Use80%

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Week One Schedule

DEFINE
Step 1: Plan Project Step 2: Define Key Measures

Lean Six Sigma Overview Define Phase

Introduction to Define Project Planning and Management Voice of the Customer Operational Definitions Types of Measures Value of Speed Rolled Throughput Yield Define Gate Review
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MEASURE
Step 3: Describe Existing Process Step 4: Validate Measurement System

Shaw Industries Group, Inc. Internal Use Only

Week One Schedule (Contd)

DEFINE
Step 1: Plan Project Step 2: Define Key Measures

Measure Phase
Introduction to Measure Value Stream Map Data Collection Plan Control Chart Theory Measurement System Analysis Subjective Measurement Analysis

MEASURE
Step 3: Describe Existing Process Step 4: Validate Measurement System

Wrap-Up
Week 2 Deliverables Exam
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Week Two Schedule

MEASURE
Step 5: Establish Process Stability Step 6: Establish Process Capability

Measure Phase
Tests for Special Causes Variables Control Charts Selecting Subgroups Attribute Control Charts Initial Control Plan Assessing Capability Measure Gate Review

ANALYZE
Step 7: Identify Key Components of Variation

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Week Two Schedule (Contd)

MEASURE
Step 5: Establish Process Stability Step 6: Establish Process Capability

Analyze Phase
Introduction to Analyze Kaizen 5S Setup Reduction Process Constraint Identification ABC Part Stratification Hypothesis Testing Comparison of Variances Comparison of Means Comparison of Attribute Data

ANALYZE
Step 7: Identify Key Components of Variation

Wrap-Up
Week 3 Deliverables Exam
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Week Three Schedule

ANALYZE
Step 7: Identify Key Components of Variation Step 8: Remove Known Sources of Variation

Analyze Phase
Correlation/Regression Work Control Conquering Complexity Quick Improvements Analyze Gate Review

IMPROVE
Step 9: Evaluate Unknown Sources of Variation Step 10: Optimize Process Step 11: Validate Improvements

Shaw Industries Group, Inc. Internal Use Only

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Week Three Schedule (Contd)

ANALYZE
Step 7: Identify Key Components of Variation Step 8: Remove Known Sources of Variation

Improve Phase
Introduction to Improve Process Flow Improvement Process Balancing TPM Replenishment Pull DOE Planning

IMPROVE
Step 9: Evaluate Unknown Sources of Variation Step 10: Optimize Process Step 11: Validate Improvements

Wrap-Up
Week 4 Deliverables Exam

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Week Four Schedule

IMPROVE
Step 9: Evaluate Unknown Sources of Variation Step 10: Optimize Process Step 11: Validate Improvements

Improve Phase
Factorial Designs Screening Designs DOE Special Topics Piloting the Solution Validation Improve Gate Review

CONTROL
Step 12: Implement Control Plan
Step 13: Demonstrate Long Term Stability and Capability Step 14: Document Results

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Week Four Schedule (Contd)

IMPROVE
Step 9: Evaluate Unknown Sources of Variation Step 10: Optimize Process Step 11: Validate Improvements

Control Phase
Introduction to Control Mistake Proofing Visual Controls Management and Control Systems Long Term Validation Project Documentation Control Gate Review

CONTROL
Step 12: Implement Control Plan
Step 13: Demonstrate Long Term Stability and Capability Step 14: Document Results

DFSS Wrap-Up
Exam
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