University of Michigan Six Sigma Black Belt Transactional Blended Course Syllabus

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1 University of Michigan Six Sigma Black Belt Transactional Blended Course Syllabus Instructor and Administrative Support Contact Information Lead Instructor: Pat Hammett, PhD, MBB or bb Phone: For Content Questions/Certification Project Support Issues from Instructors: bb (please use this Group for questions) For Administrative/Online Technical Support: (please use this Group for questions) University of Michigan Six Sigma Black Belt Certification Requirements: Completion of all required Lectures (See list below or outline tab) Completion of all TESTING EXERCISES and Case Studies with cumulative score > 80% o Exercises may be found in the 'Testing' Section and should be completed after viewing the lectures included in each test per the syllabus Completion of Black Belt Certification Exam with a score > 80% Completion of a Certification Project including: o Pre approval of Black Belt Project Proposal by Industry Sponsor and a University of Michigan faculty o Approval of actual project (see Project Guidelines) o Letter of support from industry sponsor/manager attesting to the impact of the Black Belt project ( is fine). Note: Since actual implementation of a candidate's project may be outside their control, the University evaluates projects based on the approach, proper use of course tools/methods, and the potential for improvement. Black Belt Certification Project Information: See Assignments Tab for information on: Submitting Project Proposals Sample Projects Certification Project Report Writing Templates (Word Document) Teamwork Policy (Note: our expectation is that each student will complete their own certification project report, though we will accept teams up to two upon request). Pre read/supplemental Material: What is Six Sigma?, by Donald P. Lynch Basic Statistics Refresher 1

2 Session Topic Testing Exercise (Session #) 1A/B Course Overview (A) and Six Sigma Overview (B) 2 Project Identification and Selection 3 DMAIC Problem Solving Process 4 Voice of the Customer Requirements Gathering Overview of Descriptive Statistics, Sampling, and 5 Introduction to Hypothesis Testing (One Sample Tests) MEASURE: Measuring the Current State 6 Continuous Y (Graphical Tools, Yield, PPM Defective) 7 Minitab Tutorial Ex 1 (S# 1 7) 8 Measure Current State Using Defect Count Data (Yield, Rolled Yield, Tabulation, Check Sheets, and Pareto Analysis) 9 Survey Methods and Analysis Voice of the Customer Analysis 10 Qualitative Process Analysis and Process Maps (Process Map, Cause and Effect, P Diagram) 11 Value Stream Mapping Analysis (Current and Future State VSM) Case Study 12 Minitab Session Measure Phase Ex 2 (S# 8 12) Assessing Process Stability Variable Control Charts (X Bar/Range, I/MR) Statistical Process Control: Attribute Charts (e.g., p chart, u chart) 15 Minitab Session SPC Ex 3 (S# 13 15) 16 Process Capability Analysis Normal/Non Normal Distributions 17 Sigma Level and Six Sigma 18 Minitab Session Process Capability Ex 4 (S# 16 18) 2

3 Session Topic Testing Exercise (Session #) 19 Two Group Hypothesis Tests (F tests, t tests, 2 Proportion) 20 One Factor ANOVA Operating Windows 21 Power and Sample Size Planning 22 Minitab Session Hypothesis Testing Ex 5 (S# 19 22) Case Study 23 Nonparametric Hypothesis Tests Ex 6 (S# 23) 24 Transactional Measurement Systems Analysis (MSA) 25 Repeated Measurement Study and Attribute Agreement Analysis 26 Minitab Session Transactional MSA Ex 7 (S# 24 26) 27 IMPROVE Phase Countermeasures and Short Term Verification 28 IMPROVE Phase Standardized Work and Load Leveling 29 CONTROL Methods of Control and Visual Controls 30 Transactional FMEA Improving Methods of Control (Detection) 31 Two Variable Analysis Simple Linear Regression/Correlation 32 Multiple Regression / Stepwise Regression/Best Subset 33 Binary Logistic Regression Analysis Ex 8 (S# 27 30) 34 Minitab Session Regression Ex 9 (S# 31 34) 35 Principles of Design of Experiments (DOE) 36 DOE 2k Factorial 37 Minitab Session Design of Experiments Ex 10 (S# 35 37) 38 Categorical Data Analysis Measures of Associations 39 Minitab Session Categorical Data Analysis 40 Tolerance Analysis Ex 11 (S# 38 40) 41 Course Summary 42 Certification Exam Review Session Practice Exam Case 1: Mandelbaum Case 2: Poppy's Pizza Case 3: Reliable Health Care 3

4 Lean-Productivity Analysis (Lean-Six Sigma Black Belt) Session Topic Testing Exercise 43 Lean Six Sigma Integration 44 Conducting a Kaizen Event 45 Measure: Productivity Analysis (Takt, Throughput, Nominal vs. Effective Time, Total Time in System) 46 Capacity and Utilization (Nominal vs. Effective) 47 Corrupting Influence of Flow Variability 48 Capacity Planning and Analysis 49 Load Leveling Analysis (Operator Bar Charts) Standard Work Analysis (Time observation, capacity 50 planning sheets, detail job instructions, Leadership Standardized Work) 51 Flow Improvements (One Piece Flow, Little's Law, Layout) 52 Implementing Pull Systems (Kanban, FIFO, CONWIP) 53 Process Modeling and Monte Carlo Simulation (Optional) Supplemental Material (Not Covered in Certification Exam) Session Topic Testing Exercise 54 DMAIC Project Management Project Roles 55 Visual Controls 56 Design Scorecard and Desirability Index 57 Total Productive Maintenance (TPM) OEE 58 Measurement Systems Analysis: Gage R&R Study 59 Multi Vari Analysis 60 DOE Fractional Factorial Designs, 3k Factorial, 2k w/ Center Points 61 Minitab Session Advanced DOE 62 Pugh Concept Selection Process (Optional) 4

5 Course Web Page: All lecture notes, homework sets, solutions, and tutorials are available through the course web page. Course Text Book: The course lecture notes have been developed from a variety of sources and created such that a textbook is NOT required. Many of the statistical tools and concepts covered are available through numerous web resources. Still, some may prefer a reference book and thus several are listed below. NOTE: No lectures, exercises, or case studies directly come from these references. Thus, it is NOT recommended to purchase these books unless you actually plan to use them for background reference. The Quick Reference Guides below have less information, but are more economical and user friendly. Of note, the Minitab help feature is very good and provides an excellent reference for additional information on the use of various tools. Reference TEXTBOOKS: Breyfogle, F.W., Implementing Six Sigma, Wiley Interscience Montgomery (2009). Design and Analysis of Experiments, 7th Edition, Wiley. Montgomery (2009). Introduction to Statistical Quality Control, 6th Edition Wiley. Doane & Seward (2007). Applied Statistics in Business & Economics, McGraw Hill QUICK REFERENCE GUIDES (LOW COST OPTIONS): George, Rowlands, Price, and Maxey (2005). The Lean Six Sigma Pocket Toolbook. Rath and Strong (2004), Six Sigma Advanced Tools Pocket Guide. Six Sigma Statistics Software: Minitab 16 or higher Software (Minitab also are fine though some menus may appear different than those shown in lecture) or equivalent software (SPSS, STAT SOFT, SAS). 5

6 Assignments (All assignments must be submitted electronically see instructions below): Test Exercises: These exercises consist of multiple choice questions based on lecture concepts. (For the exercises, multiple lecture modules are incorporated with the sessions numbers listed on the syllabus outline).the test exercises are administered using course web page and graded automatically when you hit the submit button. Each student must complete their own exercises. o Note: You should print out a copy of the questions and work on them off line prior to submitting your answers. If you are unsure of the intent of a question, please ask the course instructors rather than assuming information not present in the question. You cannot re take a test exercise, so please make sure you have considered your answers carefully before submitting. Ex # Topics #1 DMAIC, Data Patterns, PPM #2 DPMO, Basic Quality Tools, Process Maps #3 Statistical Process Control #4 Process capability: Normal, non normal #5 Hypothesis testing: F test, t test, ANOVA, 2 Proportions #6 Nonparametric Hypothesis Tests #7 Transactional MSA #8 Improve/Control Phase, FMEA #9 Regression Analysis #10 Design of Experiments: Factorial Analysis #11 Categorical Data Analysis and Tolerance Analysis Case Study Assignments: These assignments are intended to reinforce key course content within an actual problem solving scenario. Participants should begin a case study after the session in which they are listed on the above outline. While participants do not need to complete the case study prior to viewing the next lecture, we recommend doing so to reinforce key concepts through that point in the course. Case study reports must be ed using a single report file (See Case Study Electronic Submittal ). Acceptable file formats: (Adobe PDF or MS Word) See Case Study Report Requirements. Case # Topic Points #1 Mandelbaum AP Basic Quality Tools 30 #2 Poppy s Pizza Process Stability, Capability, and Hypothesis Tests 30 #3 Reliable Health Systems 40 Case Study Assignments should be completed either individually or in teams of 2 3. For teams, you should submit a single solution for all members. If you do not have a team and would like one, please contact the course instructors for help in setting up a virtual team. (Note: Due to the asynchronous nature of the course, we cannot always find students a team member.) Additional case studies may be available upon request. 6