The Official Council for Six Sigma Certification Lean Six Sigma Black Belt Certification Training Manual January 2018 Edition Presented by: The Council for Six Sigma Certification2017 The Council for Six Sigma Certification. All rights reserved, Harmony Living, LLC, 442 N. Main St, Suite 100, Buffalo, WY 82834 January 2018 Edition Disclaimer: The information provided within this eBook is for general informational purposes only. While wwe try to keep the information up-to-date and correct, there are no representations or warranties, express or implied, about the completeness, accuracy, reliability, suitability or availability with respect to the information, products, services, or related graphics contained in this eBook for any purpose. Any use of this information is at your own risk. ‘The author does not assume and hereby disclaims any liability to any party for any loss, damage, or disruption caused by errors or omissions, whether such errors or omissions result from accident, negligence, or any other cause. This is a free eBook. You are free to give it away (in unmodified form) to whomever you wish. Page | 2 © 2017 The Council for Si Sigma Certification. All rights reserved.Using the most recent edition in your workplace? Because we continually attempt to keep our Handbook up to date with the latest industry developments, be sure to check our website often for the most recent edition at ‘www.sixsigmacouncil.org, Page | 3 © 2017 The Council for Six Sigma Certification. All rights reservedTable of Contents UNIT 1: INTRODUCTION TO SIx SIGMA. (CHAPTER: WHAT is Su Sioa? 9 Data Driven Processes and Decisions. 9 Defining 6 nme smnnninnnennnninnnnnnaninnnennnnninnenennnaninnenennnesnsen TO Common Six Sigma Principles B Challenges of Six Sigma. 15 ‘CHAPTER 2: Sx SIGMA HISTORY AND APPLICATION 18 The Development of Statistical Process Control. 18 Continuous Process Improvement: Toyota ond Lean: 19 ‘Motorola's Focus on Defects, 20 A88, Allied Signal, and General Electric. annie 21 Continued Growth of Six Sigma. 22 Applying Six Sigma Knowledge wrnienrnnsninnneniiitinaninaniiininininnnninininnenesnnansnndd ‘Chapren 3: OTHER PROCESS IMPROVEMENT AND QUALITY METHODS, 26 Other Formal Quality or Process Improvement ProgrOMS sr.vn.n:nnnneninnnnnsen ven 28 When to Use Six Sigma 2 (CHAPTER: LEAN CONCEPTS. nnsnnnminnininnminninnninininnnninmnnnninininnnnnnnnnnnnn SS The Seven Muda. 3 Other Forms of Waste a1 Two Types of Muda. a2 Justin-Time Manufacturing, 44 ‘CHAPTER 5: BASIC Six SiGMA CONCEPTS, . 46 Stondard Deviation vorieninoninninannininniniieninninnininnnnninninnnnnnninennnnnnn AS The Pareto Principle. 52 Voice of the Customer. rueninniittnininininteinininininiinninininnnnininininineneininninnenieST Basic Metrics. 61 CHAPTER 6: APPROACHING THE PROBLEM ..rsnnsnnnminininnnnininininninnnnnininmnnnnnnnnsnnnn 6S Problem Functions: y =f). 65 The 5 Why... senna sonnei 66 Creating o Problem Statement. 68 UNIT 2: PROJECTS AND PROCESSES.. CHAPTER 7: WHATIS A PROCESS?, B What isa PrOCESS?srnnnsnn smn snnnnnnnennnnnannnenn TE Major Process Components 75 Process OWNS snennnsnninnenninanninnnnininninninnnenn sennnnnennennnnnnnnene DD Data 79 Defining Process Components: The SIPOC. 79 Tips for a SIPOC Brainstorming Session 2 Sample SIPOC Diagrams. 82 (CHapren 8: QuauiTy 88 Critical to Quality Characteristics. 88 The CoQ and the COPQ. 0... sani sonnei Page | 4 © 2017 The Council for Six Sigma Certification. All rights reserved.Quality is Critical to Success... (CHAPTER: SELECTING THE RIGHT PROSECTS Juggling the Right Amount of Projects. Enterprise-Level Selection Process See for Yourself... o (CHAPTER 10: Basic SucSIGMA TEAM MANAGE Building a Six Sigma Team Timelines, Scheduling, and Milestones. Budgets rneninenennnannenenennannenrn (CHAPTER 11: INTRODUCTION To DMAIC AND DMADV. DMAIC versus DMADV. Define. Measure. Analyze, Improve. Control. Design Verify. set Breaking up the Elephant. UNIT 3: ADVANCED DMAIC (Chapren 12: Deri Creating a Project Charter Project Ground Rules. Define Toolset. Define Tollgate Checklist. (CHAPTER 13: MEASURE. Failure Modes and Effect Analysis: Collecting Data. Measure Tollgate Checklist. (CHAPTER 14: ANALYZE Root Cause Analysis... Graphical Analysis. Statistical Analysis Analyze Tollgate Checklist. (CHAPTERS; IMPROVE Solutions Selection Matrix. Cost Benefit Analysis Piloting a Solution. Planning implementation... Improve Toligate Checklist. (CHAPTER 16: CONTROL Revise FMEA. Create a Control Plan.. Visual Management... SPC Charts Team Celebration and Reflection. Contro! Tollgate Checklist 98 99 99 99 108 110 1110 15 old 321 od22 124 125 126 17 128 128 129 130 aan 131 131 134 135 138 1a 14 143 158 159 159 163 170 172 373 173 176 17 179 180 181 181 vol 184 184 187 187 Page | 5 © 2017 The Council for Six Sigma Certification. All rights reserved.UNIT 4: BEGINNER STATISTICS. (CHAPTER 17: INTERMEDIATE GRAPHICAL ANALYSIS 189 Additional Graphical Analysis Tools. 189 Creating an X-Bar Control Chart without Statistical SoftWOr€...u.unnsnnnnsnne « 1203 Adding Free Data Analysis Tools to Excel. 208 (CHAPTER-18: NORMAL PROBABILITY DISTRIBUTIONS snninnnininnnnninininnnnninnnenninnnnnennsnn 2 Probability distributions. 214 Creating a Histogram in Excel wrnmennnmnnnnonenrennaninenninnin snnnnnennennnnnnnen 2B Normal Distributions. 1228 Normal Probabilties n.ronnsnnmninininnnennninnnennnnsn sonnnnnnnennnnnnnen DB (CHAPTER 19: CORRELATION AND REGRESSION 206 COFEIALION wsnennnsnininennnsneninnnananninnnnnen snnnnnnennnnnnnen 26 Linear Regression Analysis. 1255 Using Correlation and Regression in Six Sigma. 262 UNIT 5: INTERMEDIATE STATISTICS.. (CHAPTER 20: NON-NORMAL PROBABILITY DISTRIBUTIONS 267 Reviewing Normal Probobility Distributions 1.267 ‘Non-Normal Continuous Distributions. 268 ‘Non-Normal Discrete Distributions.. snninininnninmnineniininnninnnninnenininennnnenn BL Applying Data to Real-World Situations 296 (CHAPTER 21: HYPOTHESIS TESTING o 297 Hypothesis Test Basics 297 Selecting the Right Hypothesis Test smn snnninnnennnnn 9D Why Run Hypothesis Tests 305 Running Hypothesis Tests... smmnnmnenenmnninenenesninninenmennnannenmnannnanenennaenn 305 (CHAPTER 22: SAMPLE Size 315 A Review of Hypothesis Testing Errors. 316 What Information is Required for Choosing Sample Size? 316 Sample Size Calculations: Choosing the Right Method. 319 Running and Analyzing Sample Size Tests in Minitab. 320 (CHaPTeR 23: ADVANCED CONTROL CHARTS 331 Common Control Chart Types and When to Use Them... stnnnnnnninnnennnnnnnee SSL Creating ond Reading Control Charts in Minitab. 338 (CHAPTER 24: APPLYING STATISTICS TO BUSINESS APPLICKTIONS THROUGH SX SIGMA nan ns sn 361 ‘Common Challenges When Presenting Statistical Analysis 361 Why Include Some Statisties?....2:nsnonnmnninsnninmnnnininninnnninannnnns ven Tips for Creating Business-Friendly Presentations. 362 UNIT 6: ADVANCED CONTROL. (Cunoren25:IntRoBUCTION To MITA 372 Overview of the Minitab Interface 372 Overview of the Minitab Menu 378 The Cole Menu Option. 378 ‘Cimoren 26: Gravis AND QUALITY TOOLS IN MINITAS 396 The Graph Menu Option 396 The Stat Menu: Quality Tools. 426 Goge Stuales 436 Page | 6 © 2017 The Council for Six Sigma Certification. All rights reserved.(CHAPTER 27: THe STAT MENU IN MINITAB. 4a. Bosic Statistics. Stotistical Tests. UNIT 7: EXPERIMENTS ‘CanoTeR 28: ANALYSIS OF VARANCE (1-WAY ANOVA .snsnsinsnsnninsninnnsnininnininnnnhSS Preparing fora 1-Way ANOVA. 456 Running 01-Way ANOVA. ....ssnsnsnsninnsnsninnsnnnnanns - 457 (ChnoreR 28: Desi oF ExrERIMENTs. ar When Anaiysis Can Occur on Existing Data srnsinnnnsniniinninnnnsansenannannsnasATT Why Run an Experiment? 478 Best-Guess Tral-and-Error versus Factorial Experiments 479 What is Factorial Experimentation? 480 ‘Step-by-Step Guide for Creating a Designed Experiment. 481 Step-by-Step Guide to Running a 2k Factorial Experiment in Minitab 488 Next steps 500 (ChaoTeR 30: INTERACTIONS, MULT/-LEVEL FACTORIAL AND CREATING EXPERIMENTS son The Importance of Understanding Interactions. S01 2k Factorials Versus Multi-Level FaCtOHA!S..mssnsnnuinininnansinnnninnnnnnnnnnnnenn SE Tips for Creating Successful Designed Experiments 13 UNITS: MINITAB ‘Chaoren 31: BRAINSTORMING AND PROCESS IMPROVEMENT Tools. 516 ‘Activity Network DiagransnsnnsnnnsnsiniensnsnnnainsnnninnnanannnnnsnsnsensnSE6 Affinity Diagram. 517 Interrelationship Diagram....nsnsnnnsninnnnnsninsinininnnannananinninnnaninneST® Force Field Analysis, 519 Responsibility Chart 520 ‘Nominal Group Technique S21 Check sheets 522 SWOT Analysis 522 Storburst Brainstorming. 523 Role-Play or Figuring Brainstorming scnnnnnnsninnininnannnsninnnnnsS2® Broinwriting 24 Brainstorming AON ssesnstnniinnniinnninininiinininnnnninninnsS2B Ccunoren 32: Process Mars 527 Why Create Process MOpS..snsnsinsinsnnsnininsninsnnsnnsnsaninnnsnnsnniensnsne SST Two Types of Process Map. 527 Process Map SyMbOls..nsssnssnnnisninninnsninnsnsninnnsnnnnnnnsninnninnS28 Basic Flow Charts 535 Creating a Swimlane Diagr aM w.nnsisnsennsnsnnnsnsaniensnsnnnnninnsnannsnnneS36 Tips for Creating Concise, Attractive Process Mops. 542 (CHaoTER33: VALUE STREAM MAPPING. 50a What is Value Stream Mapping? 546 Volue Stream Map SymbOI0GY..rn0ninnsinsnninsinnsnansn crn Value Stream Mapping Tps..unsinssnensininnnninsininninininininninnniannsnieSSO Value Stream Mapping Steps 550 What Do You Do with Value Stream Maps? sentnntinnnnninininnnnnnnnnne SS Tips for Creating a Future-State Value Stream Map 585 Page | 7 © 2017 The Council for Six Sigma Certification. All rights reserved.