Welcome To Six Sigma

Black Belt Training Expectations

and Course Syllabus
 Dick Kelbaugh
President Route Six Sigma, LLC
 BS INDM Purdue 1965
 MBA Roosevelt University 1974
 US Navy 1965 – 1975: Surface Warfare Officer
 GE Appliances 1977 – 2001
 Manufacturing Engineer
 Manager Range Fabrication
 Coordinator GEA Quality Circles
 Continuous Process Improvement; Process Mapping;
Workout
 Certified Master Black Belt
 Six Sigma Training Manager
 Bloomington IN Plant Six Sigma Start up
 Senior Member of ASQ
 Certified Quality Engineer
 Board of Directors AQP; Region Director Ohio; Indiana;
Michigan and Kentucky
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 Six Sigma Basic

This is a lecture, lab and application course designed to enable

individual participants to gain a useable knowledge of basic data
based decision making tools and methodologies and apply that
knowledge to a business related problem. The prime technology
tool introduced is Minitab Statistical Analysis Software.

At the conclusion of the course, the student should be able to:

1. Identify appropriate tools and methodologies for making data based
decisions in a variety of business scenarios.
2. Complete a full project using the DMAIC Six Sigma methodology.
3. Demonstrate broad knowledge of the tools of Six Sigma through
application and interpretation of output.
4. Transition between using DMAIC methodology to DMADV
methodology where appropriate.

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 Course Schedule

Define: (2) August 25 - 26

Introduction to Six Sigma, Project Definition and Managing the Six
Sigma Project
Measure: (5) September 15 - 19
Basic Statistics; Introduction to Minitab; Measurement System
Analysis; Capability Analysis
Analyze: (5) October 13 - 17
Hypothesis Testing; ANOVA; Regression Analysis
Improve: (5) November 10 - 14
Design Experiments; Factorial Experiments; Taguchi Designs;
Fractional Factorial Experiments; Response Surface Designs
Control: (5) December 8 - 11
SPC; Project Documentation; Design for Six Sigma; Poka Yoke

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 Six Sigma Black Belt Training - Define
Monday Tuesday Wednesday Thursday Friday
9:00 First Project
Welcome –
Expectations Discussion
and Course
Define Phase
Schedule
Translating
10:00 Via Systems
the VOC into
Expectations
CTQ’s
The Six
Process Mapping
Sigma Route
12:00
Lunch Lunch Lunch Lunch
12:30
The Nature of
Data
2:00
The Six Sigma The Project
Process Charter
3:30 Roles
Managing
What Makes a your Project
Good Project
5:00
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 Six Sigma Black Belt Training - Measure
Monday Tuesday Wednesday Thursday Friday
9:00
Status Introduction Analyzing
Measurement Discrete
Report to Minitab Continuous
System Data
Analysis Data Baseline Analysis
10:00 Continuous
Data

12:00
Lunch Lunch Lunch
12:30
MSA - Discrete (Catapult Review
Data Baseline) and Next
2:00
Steps
Basic
Statistics Measure Phase
3:30 Planning
Baselining

5:00
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 Six Sigma Black Belt Training - Analyze
Monday Tuesday Wednesday Thursday Friday
9:00
Status Hypothesis Hypothesis One Variable
Report Review
Testing Testing - Regression
& Next Steps
•1 Sample Discrete Data
10:00 •2 Sample

(M&M’s) Post Test

and
Discussion
12:00
Lunch Lunch Lunch Lunch
12:30
Sample Size ANOVA Multiple
& Risk Regression
2:00
Analyze
Phase
3:30
(Catapult
Change)
5:00
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 Six Sigma Black Belt Training - Improve
Monday Tuesday Wednesday Thursday Friday
9:00
Status Fractional Helicopter
Experimentation Catapult
Report Factorial Optimization
Experiment
Experiments
10:00 2X2
Experiments

12:00
Lunch Lunch Lunch Lunch
12:30
Full Factorial Taguchi Report out
Experiments Response
Experiments
2:00 Surface
Improve Experiments Post Test
Phase and
3:30 Planning Discussion

5:00
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 Six Sigma Black Belt Training - Control
Monday Tuesday Wednesday Thursday Friday
9:00
Status SPC Project
Documentation Application
Report Closure
Exam
and
10:00 Transition
Lean
Manufacturing
Concepts

12:00
Lunch Lunch Lunch Lunch
12:30
Other Control Design for Application
Tools Six Sigma Exam
2:00
Control
Phase Post Test
3:30 Poka Yoke and
Discussion

5:00
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 Session Schedule
 Project Status – During Measure – Control phase
classes, first six hours will be set aside for project
reviews, using six sigma tools and language. Reports
should be prepared and rehearsed. We have
allowed about 15 minutes per person.

 Class Workshops – During all phases the class will

from time to time be given workshop activities.
Some may be given as end of day / overnight work.

 Computer Based Testing – Beginning in Measure, the

class participants will be asked to log on to the Six
Sigma Website and complete a test of material
covered in that phase.

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 Training Expectations
Homework
 Between Session study and application
 Within session work shop activity
 Project Application
 Stay on track with your project.
 Status Reports
 Reports will focus on key Six Sigma data revelations and action plans
based on data.
 Data analysis and reports will use Minitab outputs where appropriate.
 In addition to data output analysis, each status report will include
statements of:
Accomplishments since last status report
Barriers to project movement / completion anticipated
Milestones planned to keep project on track for completion.
 Build portfolio
 Beginning with Analyze session status report( October), complete
define phase and project charter for one project each month.
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 Status Reports
Phase Status Planned Work Report Items

Define Project charter  Process Map with key measure points

Team definition  Project charter
 Team defined
 ABM’s
Measure Project Y Project Y
Measurement System Validation Gage R&R or % Agreement
Baseline capability Baseline Z Score
Gap to close ABM’s
Analyze Identify factors(x’s) Identify factors (X’s)
Hypothesis Testing; ANOVA, etc Show tools used
ABM’s
Improve Determine improved process settings Method used to determine new settings
Confirmation Run status
ABM’s
Control Control Plan for sustainability Control Plan Status
SOP’s written SOP documentation Status
Team Trained Operational Closure Status
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Operational Closure Open Issues Milestones
 Getting Help!!
 DO NOT hesitate to contact Jack or me for help with a Six
Sigma problem.
 My address and phone number are on my business card.
 My time is 12 hours behind you. Call during your early
morning hours.
 I will try to respond to internet communications within one
business day.
 Use internet first if you have a question about your project
in Minitab. Always send a file so I can work with you. We
will often follow up with phone discussion.

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