1. Sigma Lean Execution Plan for Black Belts
Discussion Document
           
Sigma Lean Execution Plan for Black Belts
August 11, 2003
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2. Six Sigma Academy Breakthrough Strategy
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3. Knowledge Transfer Philosophy for Black Belts
Lean
Major portion of knowledge transfer occurs through “apprenticeship” relationship between Lean Master and Black Belt established from “On-site Lean Events"
Class room workshop augments knowledge transfer approach from Lean Events
Six Sigma
A great deal of knowledge transfer occurs in class room
Project execution by Black Belt reinforces concepts practiced in class
Master Black Belt mentoring accelerates the speed of project execution by Black Belt
Change Management
Change management tools are embedded within Six Sigma and/or Lean class room knowledge transfer
SigmaLean
Combination of Lean, Six Sigma and Change Management implementation approaches
Solve both Lean and Six Sigma type problems using the 12 step problem solving frame work
Apply Lean thinking to Six Sigma approach and Six Sigma thinking to Lean approach

4. SigmaLean Deployment Flow
Assessment and Project Identification
Identify projects for SigmaLean Black Belts
Projects will range from “end-to-end process” problems (traditionally solved by Lean tools) to tough narrowly scoped variation reduction problems (usually solved with the help of statistically based Six Sigma tools)
Fastart Session
Each SigmaLean Black Belt will come to the class with two projects – one primary project and one secondary project
During the Fastart session, the project is scoped with the help of Six Sigma Academy Master Black Belt
Fastart session will serve as an orientation session and to introduce software used in the class (Minitab and SigmaFlow)
Week1 Black Belt Workshop
The 12 step methodology introduced to solve any SigmaLean problem
Project Execution for Three Weeks
Black Belt starts applying classroom learning from Week1 to his/her project
Mentoring support by Master Black Belt instructor

5. SigmaLean Deployment Week2 Black Belt Workshop
Class room workshop on Lean, Six Sigma and Change Management topics
Project Execution for Three Weeks
Black Belt continues application of learning from Week2 to his/her project
Mentoring support by Master Black Belt instructor
Additional support from Lean Master to analyze “end-to-end” process problems
Week3 Black Belt Workshop
Black Belt continues application of learning from Week3 to his/her project
Prepare for lean implementation
Site leadership engaged

6. SigmaLean Deployment Week4 Black Belt Workshop
Class room workshop on Lean, Six Sigma and Change Management topics
Project Execution for Three Weeks
Black Belt continues application of learning from Week4 to his/her project
Mentoring support by Master Black Belt instructor
Lean implementation with active support from Lean Master and site leadership
Report out to site leadership
Week5 Black Belt Workshop
Project Execution and Wrap-up
Black Belt continues application of learning from Week5 to his/her project
Additional support from Lean Master to ensure controls are in place on lean implementations

7. SigmaLean Sample Curriculum
Week 1 Workshop
Introduction and Agenda
Intro to Lean and Lean Thinking
Intro to Six Sigma – Fundamentals
Six Sigma Aacdemy's Breakthrough Strategy
The 12 Step Breakthrough Strategy
Data Types
Basic Statistics
Metrics
Team Building, Effective Meetings
Introduction to Define
Customer Values
Project Selection and Definition
Six Sigma Project Management
Process and Value Stream Mapping
Project Financial Management
Kaizen activity pre-improvement- Credit Card Case Study, Round One
Presentations 15 minutes each
Support Week: Scope and Align Projects

8. SigmaLean Sample Curriculum
Week 2 Workshop
Review of prior week
Value Stream Mapping & Lead Time
Types of Waste
Workplace Organization
Tools to make Waste Visible (Including Waste Walk)
Standardized Operations
Lean BP Workshop 10 method Toolbox
Workshop Report Outs
Kaizen activity post-improvement - Credit Card Case Study, Round Two
Data Collection
Graphical Analysis
Intro to Define
Intro to Measure
Cause and Effect Tools
FMEA
Measurement Systems Analysis
Process Capability
Process Capability for Non-Normal Data
Multiple Variable Studies
Review of Define Phase
Review of Measure Phase
Review of the 12 Steps
Deliverables due Week 3
Presentations 15 minutes each
Support Week: Current State Analysis with Lean Master

9. SigmaLean Sample Curriculum
Week 3 Workshop
Review of Define/Measure
Intro to Analyze
Central Limit Theorem
Confidence Intervals
Intro to Hypothesis Testing
Hypothesis Testing – Means
Hypothesis Testing – Variation
Hypothesis Testing – Proportions
Hypothesis Testing – Chi-Square
Analysis of Variance (ANOVA)
Common Assumptions
Correlation and Simple Regression
Analyze Wrap-up
Presentations 15 minutes each
Support Week: Sigma Lean Project Coaching +
Current State Analysis with Lean Master

10. SigmaLean Sample Curriculum
Week 4 Workshop
Review of Analyze
Intro to Improve
Intro to DOE
Full Factorial DOE
2K Full Factorial
Fractional; Factorial
Center Points
Blocking
Power and Sample Size for DOE
Multiple Regression
Implementation of Improvements
Classroom DOE exercises
Wrap-up of Improve
Presentations 15 minutes each
Support Week: Sigma Lean Project Coaching +
Lean Kaizen Implementation

11. SigmaLean Sample Curriculum
Week 5 Workshop
Review of Improve
Principles of Robust Design
Intro to Response Surface Methods (RSM)
Central Composite Designs (CCD)
Multiple Response Optimization (MRO)
Introduction to Control
Sustaining the Gains
Control Plans
Standardized Work
Mistake Proofing
Intro to SPC
SPC – Variables
SPC – Attribute
Other Corporate and Quality Initiatives
Intro to DFSS
Project Close Out
Course Wrap-up
Presentations 15 minutes each
Support Week: Final State Kaizen Action Workout

12. Sample Deployment Plan
Training
Key Tasks
Breakthrough Diagnostics™
Pre-Deployment
Executive Summit
Leadership Overviews
Executive/Champion Workshops
Identify Black Belts
Prioritized Deployment Plan
Tailor Training Materials
$Project Savings / Benefits Occur
Wave 1-2 Black Belt
Project 1
Project 2
Project 3
Project 4
Wave 3-4 Black Belt
Project 1
Project 2
Project 3
Project 4
Deliver Results
Wave 5-6 Black Belt
Project 1
Project 2
Project 3
Project 4
Week 1
Master Black Belt
Green Belt
Project 1
Project 2 2 3 4 5 7 8 9 6 10 11 12 1 13 14
Month 15

13. Trademarks and Service Marks
Six Sigma is a federally registered trademark of Motorola, Inc.
SigmaFlow is a trademark of Compass Partners, Inc.
MINITAB is a trademark of Minitab, Inc.
VarTran is a trademark of Taylor Enterprises.
The following are trademarks of Six Sigma Academy as of March 2003 (alphabetical):
Breakthrough Design
Breakthrough Execution
Breakthrough Lean
Breakthrough Sigma Lean
Breakthrough Six Sigma
Breakthrough Strategy®
Breakthrough Value Services
Design for Six Sigma Software
Design Six Sigma for Software
Design with the Power of Six Sigma
ESSENTEQ
FASTART
INTELLEQ
METREQ
SigmaCALC®
SSA Navigator
Weaving excellence into the fabric of business.
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14. Six Sigma Academy
Phone: (480)
Fax: (480)
8876 E. Pinnacle Peak Road
Suite 100
Scottsdale, AZ 85255