Six Sigma Black Belt Course

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  • 1. Holland Innovative BV The partner for Innovative Solutions! Six Sigma Black Belt Course Six Sigma is a methodology introduced with success by Motorola in the nineties and thereafter adopted by Jack Welsh of General Electric. Six Sigma is a structured project approach to achieve quality and efficiency improvements. Starting point is taking decisions based on data. In that way, fact based can be worked on the financially most attractive projects. Tools that have been developed in last decennia will be applied at the right places in the methodology. The Six Sigma DMAIC methodology is usually used for projects aiming at improvements, while the Design for Six Sigma IDOV methodology is applied for design and engineering processes. Target group The Six Sigma Black Belt course focuses at people within a company involved in managing improvement projects or projects to develop new products. The course participants should at least have a Higher Vocational Education or a university degree. Some statistical knowledge has a preference. The course is especially directed towards people with an engineering background and focuses on design for Six Sigma and product reliability over life (Reliability). The organizers Holland Innovative and IBIS UvA Holland Innovative is a company that focuses itself amongst others on offering Innovative Solutions to the business community. These Solutions are often based on Six Sigma methodologies. Together with other companies convinced of the power of these methodologies, Holland Innovative and IBIS UvA started the DfSS Dommel Valley platform. For this platform Holland Innovative organizes in cooperation with IBIS UvA the Six Sigma Black Belt course. People of companies not linked to this platform may also participate in these courses. IBIS UvA is the Institute for Business and Industrial Statistics, connected to the University of Amsterdam. It is the center of knowledge in the area of Six Sigma in the Netherlands. Both companies gained a lot of experience in Six Sigma over the last years, applying the methodology to leading Dutch and international corporations. Their experience gained has resulted in the development of a certified Six Sigma Black belt course, in which many case studies will be discussed. The course will mainly be taught by teachers from IBIS UvA, who also take responsibility for the quality level of the course. The Black Belt course The participants will be trained to so-called Black Belts. These are people who execute projects according to the Six Sigma methodology. To increase the effectiveness of learning the Six Sigma methodologies and related tools, the participants are supposed to execute a first project simultaneous with the course. Subjects During the course the steps in above mentioned DMAIC and IDOV methodologies will be explained. Explaining IDOV we will also address product reliability over life (Reliability). Presentations will be alternated with case studies and exercises. Further attention is paid to statistical techniques, which will be taught using the statistical software program Minitab. A further aspect of the Six Sigma approach is the development of the required social skills to execute projects well. Successful projects are lead by well educated Black Belts. Their success is partly determined by their capabilities to strategically lead their projects. Attention is paid to further develop these skills. For a rough curriculum of the course, see the appendix at the end of this document. Certificate Participants who finish the 16-days course and take the accompanying theoretical exam with success will receive a certificate of participation. The Dommel Valley Black Belt course qualifies for certification as Black Belt by the University of Amsterdam. In addition to taking the theoretical exam, two projects must be executed according to one of the Six Sigma methodologies, and must be approved by the University of Amsterdam. An important requirement for approval is that the monetary results of each project must exceed k€ 50. For project with solely non-monetary benefits the examiners will decide whether the project is of sufficient weight.
  • 2. Holland Innovative BV The partner for Innovative Solutions! Six Sigma Black Belt Course Dates The course is made up of four blocks. Each Block has four course days, followed by some weeks during which the participants can digest the material and have the time to apply it to their own projects. The blocks are daily from 09:00 - ~19:00 hours, followed by a dinner at the Grand Café on the High Tech Campus. The time from 17:00 – 19:00 hours will be used to discuss and review the projects in execution. Respecting your private time, we choose to end the course at ~16:30 on the last day of each Block. The Black Belt course will be taught twice a year – assuming sufficient participants: once in spring and once in autumn. The dates of the spring course 2010 are: Block 1: week 12 (March 23 t/m 26) Block 2: week 16 (April 20 t/m 23) Block 3: week 20 (May 18 t/m 21) Block 4: week 24 (June 15 t/m 18). Subscription and Costs The course location is the training room of Holland Innovative at the High Tech Campus in Eindhoven. Included in the course price are 16 days training in Six Sigma methodologies, meeting arrangements, extended course materials, project support on course days from 17:00 – 19:00 hours and dinners at the First three days of each Block. The costs are € 9.950 (ex VAT) per participant. Not included in the course price are the cost for the theoretical exam and certification by the University of Amsterdam (both if desired). Subscription can be done filling in the subscription form, which can be ordered via info@holland-innovative.nl or via the contact mentioned below. Subscription is also possible via the web site www.holland-innovative.nl. Number of participants Due to the nature of the course the minimum number of participants is 10 and the maximum is 16. Admission is in sequence of reception of signed subscription forms. What to bring to the course? During the course participants need a laptop with EXCEL and the statistical software package Minitab (version 15) installed. A 30-day trial version of this package can be downloaded from the website www.minitab.com. In the course room WLAN access is available to access your company Minitab license. On request also courses based on JMP are available. Teachers Head teacher and responsible for the contents of the course is Dr. J. de Mast of IBIS UvA. Additionally, specialists of the Dommel valley platform will teach special contributions, amongst others in the areas of Shainin techniques, FMEA methodology and the MBTI personality type descriptions. Information For further information about our Six Sigma courses and / or projects by Holland Innovative: Ir. Joost van der Heijden T +31 40 851 4610 Master Black Belt F +31 40 851 4619 Holland Innovative BV M +31 6 2059 7485 High Tech Campus 9 joost.van.der.heijden@holland-innovative.nl 5656 AE Eindhoven www.holland-innovative.nl
  • 3. Holland Innovative BV The partner for Innovative Solutions! Six Sigma Black Belt Course Curriculum DfSS Black Belt Block 1: Identify Orientation and project management: Six Sigma and Design for Six Sigma: business economic context; essentials of their methodology; DMAIC and IDOV roadmap Project management, including the project contract, managing teams, and working in a political force field Personality types IDOV 1–3: Determine functional requirements Translate into technical requirements (operational definitions) Create business case / value proposition Tools: CTQ flow down and critical parameter management Statistical techniques: Measurement system analysis and gauge R&R studies Introduction Minitab Elementary statistical techniques Data-analysis part I: performance studies (control charts, process capability analysis) Dommel Valley contribution: Product Creation Process in relation to Design for Six Sigma, by Henk van Haren (Bosch) Block 2: Design IDOV 4–6: Develop concept designs Establish high-level design, Pugh concept selection matrix Identify control and nuisance variables Tools: The design review Idea generation (sources for idea generation; process and product know-how; effective brainstorming; exploratory data analysis; product and process examinations; benchmarking and TRIZ) FMEA and mistake proofing Statistical techniques: Reliability engineering part I: lifetime modeling (Weibull analysis, MTBF, failure rates, hazard and survival functions, practical implications, reliability specifications, reliability apportionment) Data-analysis part II: statistical modeling (ANOVA, regression, cross tabulations, logistic regression) Project management: Diagnosing and managing political and personal resistance
  • 4. Holland Innovative BV The partner for Innovative Solutions! Six Sigma Black Belt Course Dommel Valley contribution: Case study by NXP MBTI Personality types, by Joost van der Heijden, Holland Innovative Block 3: Optimize IDOV 7–9: Determine transfer functions (CTQ-X relationships) Determine optimal settings Determine tolerances Statistical techniques: Design and analysis of experiments Robust design Tolerance design strategies Project management: Effective presentation of project results Dommel Valley contribution: Shainin’s Statistical Engineering techniques by Ko Dousma, Philips Applied Technologies Block 4: Verify IDOV 10–12: Test run and capability analysis Design quality control system Project closure and transfer Tools: Reliability engineering part II: failure analysis (DFMEA, hazard scenarios and fault trees, HALT (highly accelerated life testing)) Process improvement and control: process mapping, shop floor management, planning for control Lean manufacturing, incl. line balancing, value stream mapping, rapid changeover, 5S Statistical process control, PID controllers, and other control systems Statistical techniques: Reliability engineering part III: Accelerated life testing (ALT, regression with life data) Data-analysis part III: Analysis of unplanned data Project management: Effectuating change and implementation planning Dommel Valley contribution: Special contribution by Sensata Technologies