Lean Six Sigma Black Belt (Phase 4 & 5) – Body of Knowledge

Six Sigma Black Belt: Six Sigma Phase 4 and 5

To sit for AIGPE Black Belt Certification Exam, you are required to have completed 1) AIGPE Six Sigma Green Belt Training and 2) AIGPE Black Belt: Phase 0 & 1, Phase 2 & 3 and Phase 4 & 5 Training

5.0 Improve Phase
5.1 Generate, Prioritize and Select Solutions

5.1.1 Brainstorming

5.1.2 Benchmarking

5.1.3 Brainwriting

5.1.4 Assumption Busting

5.1.5 Modified Brainstorming Techniques

i. Analogy Technique

ii. Channeling Technique

iii. Anti-Solution Technique

5.2 Identifying Solutions – Lean Tools & Solution Selection Matrix

5.2.1 5S

5.2.2 Heijunka

5.2.3 Generic Pull

5.2.4 Autonomation (Jidoka)

5.2.5 Just-In-Time

5.2.6 Theory of Constraints (TOC)

5.2.7 Solution Selection Matrix

5.2.8 Implementation

5.2.9 SWOT Analysis

5.3 Pilot Solutions

5.3.1 What is a Pilot?

5.3.2 Implement Poka-Yoke (Mistake-Proofing)

5.3.3 Implement Failure Mode and Effects Analysis (FMEA)

5.3.4 Implementation Planning

5.4 Validate Impact of Solution(s)

5.4.1 Cost Benefit Reanalysis

5.4.2 Validate Measurement System

5.4.3 Process Capability Re-Analysis

6.0 Control Phase
6.1 Institutionalize the Solution(s)

6.1.1 Visual Management Boards

6.1.2 Team Huddles

6.1.3 Control Plan

6.1.4 Standard Operating Procedures (SOP)

6.1.5 Go Gemba

6.2 Statistical Process Control (SPC)

6.2.1 Control Charts

6.2.2 Control Limits vs. Specification Limits

6.2.3 Control Charts – In Control Processes

6.2.4 Seven Indicators of an Out-of-Control Process

6.3 Control Charts for Continuous Data

6.3.1 I-MR Chart

6.3.2 X bar R Chart

6.3.3 X bar S Chart

6.4 Control Charts for Discrete Data

6.4.1 np Chart

6.4.2 p Chart

6.4.3 c Chart

6.4.4 u Chart

6.5 Total Productive Maintenance (TPM)
6.6 Sustain Improvements

6.6.1 Lessons Learned

6.6.2 Training Plan Deployment

6.6.3 Documentation

6.6.4 Ongoing Evaluations

6.7 Implement Control Plan?

6.5.1 Control Plan

6.5.2 Process Owner Sign-off

6.6 Replicate and Share Best Practices

6.7 Celebrate and Recognize Success

6.8 Post-Implementation Review

6.9 Celebrate

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