Lean Six Sigma Black Belt Training | Lean Six Sigma Training - in Yokohama

Lean Six Sigma Black Belt Course Outline

Module 1: Introduction to Lean 6 Sigma

• What is Lean 6 Sigma?
• Lean 6 Sigma Belts
• Processes
• Customers, Value, and Waste
• Key Metrics

Module 2: Reviewing Process and Qualities

• What is DMAIC?
• Define
• Measure
• Analyse
• Improve
• Control

Module 3: Yellow Belt Tools and Techniques

• Lean Triad
• Voice of the Customer (and CTQ’s)
• SIPOC
• Value Stream Analysis
• Heijunka
• Variation and SPC
• Defects and Process Capability
• Identifying the Root Cause(s)
• Solving Problems
• Introduction to Kaizen
• Lean Teams

Module 4: Improvement Methodologies

• DMAIC
• 3Cs
• 8Ds
• Plan Do Check Act
• Kaizen
• Design for Six Sigma (DFSS)

Module 5: SPC Basics

• Terminology
• Data Types
• Normal Distribution and Standard Deviation
• Process Capability

Module 6: Lean Management and Cell Theory

• Role of the Lean Manager
• Work Cells
• High Performing Teams (HPTs)
• Rapid Action Teams (RATs)
• Visual Management
• Bruce Tuckman’s Group Development Model
• Emotional Cycle of Change (ECOC)
• Personality Styles
• Dealing with Resistance

Module 7: Risk Management

• Green Belt Risk Management
• FMEA: Failure Mode and Effects Analysis

Module 8: DMAIC for Green Belts

• Define Phase
• Measure Phase

Module 9: SPC Tools and Techniques

• Frequency Distribution Tables
• Bar Charts and Histograms
• Pareto Charts
• Box and Whisker Plots
• Normal Distribution and Control Charts
• Calculating Process Efficiency
• Scatter Diagrams and Regression

Module 10: Analyse Phase

• Analyse
• Process Maps
• Process Map Levels
• On the Ground Instructions (OTGIs)
• Value Stream Maps
• What is a Value Stream?
• Creating the “As Is” VSM
• Investigating and Understanding the Process
• Headache Tablets: Value Stream Mapping
• Creating a VSM: Process Borders Definition
• Using Swim Lane Diagrams to Identify Logical Process Blocks
• Process Boxes
• VSM Metrics
• Square Wave
• Kaizen Burst
• Creating an Improved Process
• Layout Diagrams and Headache Tablets

Module 11: Improve Phase

• Heijunka
• Solutions Identified, Selected, Planned, and Implemented
• Standardisation and Documentation
• Communications and Training

Module 12: Control Phase

• Embed the change
• Measure the gain
• Close the project

Module 13: Role of the Black Belt

• Black Belts’ Place in the Business
• Black Belt Skill Set
• Green Belts’ View of the World
• Black Belts’ View of the World
• How the Industry Identifies Black Belts?
• Who does the Black Belt Work with?
• Case Study

Module 14: Black Belt DMAIC

• How the Black Belt helps the Green Belt During DMAIC?
• Measure Phase
• DMAIC Programmes
• Governance

Module 15: Enterprise Risk Management

• Risks Lie in Two Areas
• Who Should Handle Risk?
• DMAIC Risk
• A view of Business Risk Management
• Basic Risk Management Procedure
• Business Risk Management in a Nutshell

Module 16: Physical Cell Design and Optimising Flow

• In a Nutshell
• Task & Work Cells
• Flow Improvement Objectives
• Practical Layout Design

Module 17: Black Belt as a Trainer

• Characteristics of Adult Learners
• Three Common Learning Styles
• Preparing the Training
• Top Tips
• Case Study

Module 18: Statistics Basics

• Introduction and SPC Refresh
• Common Terminology
• Flow Improvement Objectives
• Measuring Uncertainty
• Minitab Run-through

Module 19: Process Capability

• Process Capability: Review from Green Belt

Module 20: Hypotheses Tests

• Introduction to Hypotheses Testing
• Working with Hypotheses Tests
• Hypothesis Test Roadmap
• Anderson Darling Normality Test
• To Open the Worksheet
• The Results
• Testing for Means
• t-tests Consider More than Just the Means…
• t-test Exercise
• Z test
• Testing for Medians
• Where Could I Use Median Tests?
• Median Hypothesis Tests
• Testing for Standard Deviation (Variance)
• Equal Variance Hypothesis Tests
• Exercise: Test for Equal Variance
• Interpreting the Results
• Using Bartlett’s Method
• Testing for Proportions and Percentages
• Proportions and Percentages Hypothesis Tests

Module 21: Exercise Using Minitab’s – 2 Proportion Test

• Scenario
• Abbreviated Instructions
• Reviewing the Results

Module 22: Exercise Using Minitab’s - Chi-Square Test

• Scenario
• Abbreviated Instructions
• Interpreting the Results

Module 23: ANOVA

• Required conditions for ANOVA
• The ANOVA “family”
• ANOVA Terminology
• Hypotheses Tests and One-way ANOVAs
• Exercise - One-way ANOVA
• Exercise - Multi-way ANOVAs

Module 24: Data Collection Planning for Hypotheses Tests

• General Points
• Sample Size
• How a Greater Sample Size Reduces Uncertainty?
• Case Study

Module 25: Design of Experiments (DOE)

• Overview of DOE
• Where to Use Design of Experiments?
• DOE Terminology (1)
• Design of Experiments Flow Diagram
• Walkthrough: SB Glass Co
• Step 1: Investigate the Process
• Step 2: Gather Data
• Recording the Data: Building the Worksheet
• Minitab Creates an Initial DOE Worksheet
• Team Completes the Worksheet
• Step 3: Analyse Data
• Teams’ First Analysis of the Data
• Minitab does its Stuff

Module 26: Probability Distributions

• Overview
• Normal Distribution
• Binomial Distribution
• Poisson
• Exponential
• Weibull

Module 27: Advanced Control Charts

• Introduction and Refresher
• Key Control Charts
• Data Collection Planning for Control Charts

Module 28: Measurement System Analysis (MSA)

• General overview
• Key Metrics
• Using Lean Metrics

Module 29: Lessons from Queue Theory

• Overview
• Understanding Gauge R&R
• Minitab Walkthrough

Module 30: Lean Metrics

• Modelling Queues
• Psychology of Queuing

Lean Six Sigma Black Belt Exam Information

Our Lean Six Sigma Black Belt Course is divided into two modules. The first covers Yellow Belt fundamentals and Green Belt concepts, including the Define, Measure, Analyse, Improve and Control (DMAIC) methodology. The second focuses on advanced Lean Six Sigma Black Belt concepts and techniques.

Examination Requirements: Delegates must successfully pass the Lean Six Sigma Yellow Belt, Green Belt and Black Belt examinations to obtain the Lean Six Sigma Black Belt qualification.

Lean Six Sigma Yellow Belt Exam Information

The Lean Six Sigma Yellow Belt Exam assesses delegates’ understanding of core Lean Six Sigma principles, DMAIC, process improvement, waste reduction, variation, and basic problem-solving tools covered during the training. The exam format is as follows:

• Question Type: Multiple Choice
• Total Questions: 40
• Pass Mark: 70%
• Duration: 1 Hour
• Open Book/ Closed Book: Open Book

Delegates are required to attend the Lean Six Sigma Yellow Belt Training Course before sitting this exam.

Lean Six Sigma Green Belt Examination Information:

Lean Six Sigma Black Belt Examination Information

To achieve the Lean Six Sigma Black Belt, delegates are required to sit for an examination. The exam format is as follows:

• Question Type: Scenario based questions and multi choice questions
• Total Questions: 40
• Pass Mark: 70%
• Duration: 2.5 Hours
• Open Book/ Closed Book: Closed Book

Who should attend this Lean Six Sigma Black Belt Course?

This Lean Six Sigma Black Belt Course is suitable for experienced professionals involved in process improvement, quality management, operations, and organisational performance. It is particularly beneficial for:

• Senior Managers
• Project Managers
• Quality Managers
• Process Improvement Specialists
• Operations Directors
• Continuous Improvement Managers
• Supply Chain Managers
• Manufacturing Engineers

Prerequisites for the Lean Six Sigma Black Belt Course

There are no formal prerequisites to attend this Lean Six Sigma Black Belt Course. However, delegates will need a laptop with Minitab installed for the Black Belt section of the training.

A 30-day trial version can be used where appropriate, and installation details are provided with the pre-course materials. Delegates should ensure the software is installed before the training begins.

Lean Six Sigma Black Belt Course Overview

The Lean Six Sigma Black Belt Course develops advanced knowledge of Lean Six Sigma methodologies, DMAIC, statistical analysis, risk management, and process improvement. It also covers advanced tools used to analyse performance and improve operational processes.

Delegates will develop skills in interpreting process data, conducting root cause analysis, applying statistical techniques, managing risks, and leading improvement activities. They will also strengthen their ability to guide teams and support data-driven decision-making.

This 10-Day course by The Knowledge Academy helps delegates apply advanced Lean Six Sigma methods to complex process improvement initiatives. They will be better equipped to reduce variation, strengthen process control, and support sustained operational performance.

Lean Six Sigma Black Belt Course Objectives

• To enhance understanding of Lean Six Sigma methodologies at a Black Belt level
• To develop skills in leading, managing, and executing process improvement projects
• To empower delegates with advanced problem-solving and analytical tools
• To improve capability in managing team dynamics and project leadership
• To facilitate the application of Lean Six Sigma tools for quality improvement
• To enable data-driven decision making for operational excellence

Learning Outcomes of this Lean Six Sigma Black Belt Course

Upon completing this Lean Six Sigma Black Belt Course, delegates will be able to analyse complex process issues, apply advanced Lean Six Sigma tools, and lead structured improvement initiatives. They will also strengthen their ability to manage teams, evaluate process performance, control variation, and support data-driven improvement across organisations.

What’s Included in this Lean Six Sigma Black Belt Course?

• Lean Six Sigma Yellow Belt Examination
• Lean Six Sigma Green Belt Examination
• Lean Six Sigma Black Belt Examination
• World-Class Training Sessions from Experienced Instructors
• Digital Delegate Pack