Lean Six Sigma Master Black Belt Upgrade - United Kingdom

Lean Six Sigma Master Black Belt Course Outline

The Lean Six Sigma Master Black Belt training course will cover the following areas:

Module 1: Understanding Lean 6 Sigma Advanced Roles 

• Role of a Black Belt.
  • Black Belts’ Place in Business.
  • Black Belt Skill Set.
  • How Belts Work Together.
  • Black Belt Major Areas of Responsibility.
• Role of a Master Black Belt.
  • How Industry Identifies Master Black Belts.
• Board Level Champion. 
  • Role of Board Level Champion.
  • Embedded Champion Network. 
  • Champions Based on Org Chart.
  • Champions Based on Separate Structure.

Module 2: Leadership 

• Whom do You Lead? 
• Leadership Styles.
• Goals of Lean 6 Sigma Leaders.
• Gemba.
• Genchi Genbutsu.
• Working With Gemba.
• Principles of Lean Leadership.
• Key Leadership Behaviours.
• Leadership and ECOC.

Module 3: Formal 5Ys 

• Examples of 5Ys.
• Proportional Response.
  • Example of Proportional Response.
• 5Y Workshop and Champion.
• Black Belt Perspective.

Module 4: TPS, Toyota Way, and 4Ps 

• Introduction to Toyota Way.
  • Background.
  • Suppliers.
  • Holistic approach.
• 3Mu’s.
• 8 Classical forms of Muda (1, 2, and 3)
• Mura and Muri.
• Hoshin Kanri Cycle.
• Tailoring Principles.
• How 4Ps and Principles Work Together.

Module 5: Visualising and Controlling Processes Through Kanban 

• WIP: An Office Definition.
• Why is WIP Bad?
• Resource Utilisation or Flow Optimisation.
• Theory Of Constraints (TOC).
  • Benefits of Implementing TOC.
  • Shortfalls or Criticisms of TOC.
  • 5 Focusing steps of TOC.
• Lean Accounting.
• Kanban in Office.
• Cumulative Flow Diagrams (CFD).
• Kamishibai Boards.

Module 6: Total Productive Maintenance (TPM) 

• BB Interest.
• Introduction to Total Productive Maintenance (TPM).
  • TPM – Goals.
  • TPM is Needed.
  • Why Should an Organisation Embrace TPM?
• Designing for Resilience.
• Resilience Techniques.
• Six-Step Implementation Framework.
• TPM: Establish Infrastructure.

Module 7: Understanding Kaizen

• What is Kaizen?
• Kaizen as a Philosophy.
• Kaizen as an Improvement Methodology.
• Kaizen ISFs.
• Typical Kaizen Tools.

Module 8: Kaizen Events: Preparation 

• Preparation Overview.
• Setting Up Team.
• Understanding Process.

Module 9: Kaizen Events: Pre-kaizen 

• Pre-Kaizen Overview.
• Kick-Off Meeting.

Module 10: Kaizen Events: Implementation 

• Implementation Overview.
• Possible Implementation Schedule.
• Responsibilities During Implementation.
  • Sponsors.
  • Champions.
  • Facilitators.
  • Team Leader.
  • Tactical Teams.
• Daily Review Meeting.
• Tactical Teams Responsibilities to Daily Review.
• Typical Daily Review Agenda.

Module 11: Kaizen Events: Follow-Up 

• Follow-Up Overview.
• 30-Day Plan.
• Checklist.
• 30-Day Review.
• Typical 30-Day Review Agenda.

Module 12: Effective Meeting Management 

• 30-Day Review Agenda.
• What are Meetings Trying to Achieve?
• Prerequisites for Effective Meetings.
• Major Activities.
• Meeting Member’s Approach.

Module 13: Making a Case for Lean 6 Sigma 

• Cost of Quality (COQ).
• Financial Benefits of a High Process Sigma.
• Maximising Intangible Resources.
• Other Benefits of a Lean 6 Sigma Culture.
• Business Case for Lean 6 Sigma.

Module 14: Dynamics of Change 

• Core Principle.
• Waste is Everywhere.
• Business Models.
• Evaluating Business Maturity.
  • Getting started.
  • Lean 6 Sigma Maturity Levels.
  • Capability and Health Check.
• Combating Resistance.

Module 15: Strategy for Black Belts

• What is Business Strategy?
• What is Strategic Management?
• Key Stakeholders.
• Value Propositions.
• Michael Porters “Generic Strategies”.
• Treacy and Wiersema’s Value Propositions.
• Cost Leadership/Operational Excellence.
• Capabilities and Core Competencies.
• Enabling Resources.
• Communicating Strategy.
• Goals and Core Values.

Module 16: Developing a Lean Thinking culture 

• Developing L6S Culture.
• Ideal Lean Organisation.
• Clear Goals and Transparency.
• Carrying Out a Business Review.
• Possible Approaches.
• Cluster Option.
• Changing Culture by Inserting Wedges.
• Pathfinder Groups.
• Initial Skill Transfer.
• Sustaining L6S Culture.
• Hothouse ISFs.

Module 17: Lean Start-up 

• Introduction.
• Models of Growth.
• Strategy in a Lean Start-up.
• Validated Learning and Innovation Accounting.
• Testing Techniques.
• Pivots.

Module 18: Controlling Projects and Design for Six Sigma (DFSS) 

• Elements of Project Management.
• Popular Methodologies.
• Some Common Tools.