Six Sigma

Much like lean manufacturing seeks to eliminate process waste, Six Sigma seeks to eliminate process variation. Six Sigma uses data, measurements, and statistics to identify inefficiencies and eliminate defects. Any time a process fails to deliver a good product, there is a cost incurred. In a typical company, this “cost of poor quality” represents 15 to 20 percent of revenue and is often hidden. Implementing Six Sigma will improve productivity, throughput, quality, delivery times, and customer satisfaction. Additionally, you will see decreases in rework, defects, “fire-fighting”, overtime, and operating costs.

Six Sigma Solutions

The UT Center for Industrial Services offers training, consulting, mentoring and coaching assistance from qualified Six Sigma Black Belts and Master Black Belts. Trained and knowledgeable consultants can apply statistical tools and techniques to dramatically reduce your process variation and provide your customers with the higher quality products and services they constantly demand. Six Sigma Solutions can be customized and delivered at your worksite.

Six Sigma Black Belt

Six-Sigma Black Belt is for those interested in improving processes in a full-time role. Black Belts might apply the Six Sigma tools to any process within an organization, helping create tremendous measurable impacts for businesses. The Six Sigma Green Belt Solutions Program develops the technical and leadership skills of those individuals who have been selected to become Lean/Six Sigma Black Belts: continuous improvement role models, resources, and the leaders of the company's large Six Sigma projects.

Six Sigma Green Belt

Six-Sigma Green Belt is intended for those interested in improving current processes. By applying Six Sigma tools to projects closely related to their current duties, Green Belts create significant, measurable impacts for businesses. The Six-Sigma Green Belt Solutions Program develops the technical skills of the individuals selected to become key Lean/Six Sigma Project Team Members and leaders of smaller Lean/Six Sigma projects.

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Black Belt, Green Belt, and Champion Coaching

Past experience has demonstrated improved project results when individual coaching is incorporated into the training schedule. Individual coaching enhances the development process in the following ways: 

  • The coach and student are provided an opportunity to ask project specific questions.
  • The concepts can be discussed in more detail than is possible in the classroom, in the context of the student’s assigned project.
  • The coach develops a better understanding of processes and problems being worked on and can adjust materials and assignments in subsequent classroom sessions.
  • The coach helps the Black Belt develop problem solving strategies and apply Six Sigma tools to specific situations.
  • The coach provides expert problem solving ideas and solutions based on experience in many organizations and situations.
  • The coach develops a better understanding the organization culture and can better assist the Black Belts and Champions in overcoming resistance to change

Individual Coaching – Each individual coaching session will be 1 – 1½ hours. There will be a coaching session following each training session.

1.2.3 Six Sigma Black Belt Certification

Six Sigma Black Belt Certification

Purpose

To develop the technical and leadership skills of those individuals who have been selected to become Six Sigma Black Belts: continuous improvement role models, resources, and the leaders of the company’s large Six Sigma projects

Participants Learn

  • How to lead Six Sigma project teams in the application of Six Sigma and Lean Thinking technical tools to accomplish breakthrough reductions in process variation and waste
  • How to apply group process and project management skills in a way that empowers and develops both operating teams and project teams
  • How to deliver bottom line impact on projects, providing immediate return on investment while building excitement and commitment to the organization's Six Sigma strategy

Why this training is important

Developing a culture of continuous improvement using Six Sigma methods requires expertise in technical and leadership skills to successfully complete projects which impact bottom-line results. Black Belts learn these skills through this combination of training and application.

Black Belt Training Curriculum 

Agenda 

Session 1-Week 1: Define and Measure

  • Introduction to Six Sigma
  • Types and Sources of Variation
  • Project Selection and Definition
  • Introduction to Sigma Flow Software
  • Process Mapping
  • Data Collection Plan
  • Basic Statistics
  • Introduction to Minitab Software
  • Analyzing Variation (Sub-grouping)
  • Measurement Systems Evaluation
  • Effective Meetings and Facilitation
  • Project Management
  • Project Application Planning

Session 2-Week 2: Analyze

  • Process Capability
  • Kaizen
  • Quick Changeover
  • Advanced Statistics
  • Components of Variation
  • Building an Effective Six Sigma Team
  • Contracting with the Process Owner
  • Project Application Planning

Session 3-Week 3: Improve

  • Full Factorial Design of Experiments
  • Fractional Factorial Design of Experiments
  • Measuring Project Results
  • Total Productive Maintenance
  • Failure Mode Effects Analysis
  • Situational Leadership
  • Lean / Flow Concepts (Office and Factory)
  • Project Application Planning

Session 4-Week 4: Control

  • Advanced DOE Topics
  • 5S and Visual Management
  • Standard Work
  • Mistake Proofing
  • Transition Management
  • Statistical Process Control
  • Building Control Plans
  • Project Application Planning

Session 5-One Day Project Review and Certification Ceremony

1.2.4 Six Sigma Green Belt Training 

Six Sigma Green Belt Training 

To develop the technical skills of the individuals selected to become key Six Sigma Project Team Members and leaders of smaller Six Sigma projects.

Green Belt Training Curriculum

(Customized based on the needs of the organization from the following topics) Often done in 5 – two-day sessions with a final project review session 6. 

Ten Days of Training

Session 1 

Day 1

  • Introductions, Kick-off, Opening Statements by Herb, Chuck
  • Review of Key Lean/Six Sigma Concepts: DMAIC Process
  • Define and Manage Tools 
  • Review Green Belt Project Charters (5 minutes/project)
  • Plant Tour - Focus on Project Areas

Day 2

  • Introduction to Variation: Types and Sources
  • Detailed Six Sigma Process Mapping
  • Data Collection Planning
  • Project Application Planning
  • Wrap-up/Critique

Session 2  

Day 1

  • Project Reviews (15 minutes/project)
  • Analyzing Variation
  • Introduction to Minitab

Day 2

  • Measurement Systems Evaluation (Use T&B Measurement Devices)
  • Variable and Attribute
  • Failure Mode Effects Analysis
  • Project Application Planning Wrap-up/Critique
  • Headline: Session 3 

Session 3

Day 1

  • Project Reviews (15 minutes/project)
  • Process Capability Studies (Potentially use T&B Data and Processes)
  • Basic Problem Solving Tools

Day 2

  • Components of Variation / Multi-Vari Studies
  • Inferential Statistics
  • Statistical Testing
  • Project Application Planning
  • Wrap-up/Critique

Session 4

Day 1

  • Project Reviews (15 minutes/project)
  • ANOVA (Analysis of Variance)
  • Introduction to Design of Experiments

Day 2

  • Full Factorial Design of Experiments
  • Fractional Factorial Design of Experiments
  • Project Application Planning
  • Wrap-up/Critique

Session 5

Day 1

  • Project Reviews (15 minutes/project)
  • Measuring Project Results (T&B Format / Guidelines)
  • Lean Improvement & Control Tools Overview
  • 5S/Visual Management
  • Standard Work
  • Mistake Proofing
  • Quick Changeover
  • Day 2
  • Control Plans
  • Statistical Process Control
  • Pre-Control
  • Transition Management/Project Closure
  • Project Application Planning
  • Wrap-up/Critique

Session 6

Day 1

  • Project Reviews (30 Minutes/Project)
  • Certificates and Celebration
  • Wrap-up/Critique

Why this training is important 

Developing a culture of continuous improvement using Six Sigma methods requires technical expertise throughout the organization. Green Belts should be selected and developed at all levels and from all areas of the organization. They form the core of Black Belt project teams initially and with experience begin to lead projects. 

Many organizations require all managers to become Green Belts to reinforce the strategy and importance of using a rigorous problem solving process and tools.