BLACK BELT LEARNING OBJECTIVES & ASSESSMENT STRATEGY

Overview

1 Explain the benefits of Six Sigma to GEs business. CLASSROOM

Compare and contrast Six Sigmas process improvement approach to quality with traditional defect prevention strategies (i.e., inspection and testing).

Identify the vital few CTQs that apply to all GE customers: responsiveness; marketplace competitiveness; on time, accurate and complete deliverables; and product/service technical performance.

Explain the relationship between increasing levels of process complexity and quality improvement results.

2 Describe the Six Sigma Methodology for quality improvement. CLASSROOM

Define the term sigma (standard deviation) as it relates to the sigma capability (z value) of a business or manufacturing process.

Recognize a Six Sigma level of quality (i.e., 99.99966% probability that defects will not be passed on to the customer).

Define key Six Sigma terms and acronyms, including CTQ, opportunity, defect, DPMO, and Six Sigma capability (Z value).

Explain the Master Back Belt (MBB), Black Belt (BB) and Green Belt (GB) roles in Six Sigma.

Describe Six Sigmas focus on repeatable processes. Describe Six Sigmas focus on inputs (Xs) over outputs (Ys) using the

formula Y=f (X). Describe the statistical objective of Six Sigma (i.e., reduce process variation). Describe the relationship between DPMO and process capability (i.e., as

DPMO goes down, process capability goes up. Describe the financial benefits of Six Sigma to GE.

3 Describe the 5 phases of DMAIC, including the purpose, tools, and outputs for each

phase. TEST 3 QUESTIONS

4 Determine if DMAIC is the right strategy by identifying the conditions under which the DFSS methodology would be more appropriate. PROJECT

Compare and contrast the DFSS design methodologies to DMAIC.

Define

1 Recognize the components of the 12 Step Process and how they may be applied to a

Six Sigma project. TEST 3 QUESTIONS 2 Describe the purpose of the define phase and its key deliverables: CTQs, team

charter, and process map. TEST 3 QUESTIONS Identify the five key objectives of the Define Phase.

3 Select a Six Sigma project. PROJECT

Identify the characteristics of a great Six Sigma project. Recognize sources for Six Sigma project ideas. Recognize Six Sigma project success factors and common pitfalls. Identify the six issues to consider when selecting a project: process,

feasibility, measurable impact, potential for improvement, resource support within the organization, and project interactions.

4 Identify project CTQs. TEST 3 QUESTIONS Define CTQ (Critical to Quality Characteristic). Identify customer(s) in a quantifiable way. ! Recognize the components of a process (i.e., supplier, input(s), sub-process,

output(s), customer(s). ! Distinguish between internal and external customers. Compile and evaluate customer CTQ data. ! Distinguish between customer driven CTQs and process driven CTQs. ! Recognize sources of existing customer data. ! Assess customer requirements and expectations. ! Recall the vital few customer CTQs. ! Analyze the voice of the customer and its impact on CTQ data. ! Translate customer needs into requirements (CTQs).

5 Use a process/product drill-down tree to: define the limits of a project (project

bounding); clarify what the project is and is not; identify other areas for improvement. PROJECT

Create a process/product drill-down tree. Integrate measurements to clarify areas needing improvement. Given an example of a process/product drill down tree, identify viable Six

Sigma projects.

6 Develop a team charter. PROJECT Describe the purpose of a charter. Identify the five major elements of a charter. Define the business case for a project in terms of its potential benefits, the

consequences of not doing it, its relationship to other activities, and its fit with business initiatives/target.

Develop a problem statement. ! Describe the customers pain. ! Identify key considerations and potential pitfalls to consider when developing

a problem statement. Develop a SMART goal statement (specific, measurable, attainable, relevant,

time bound). Assess the scope of the project. ! Identify the 8 steps for bounding a project. Define project milestones. Select a project team and define team roles. ! Identify team roles and responsibilities. Evaluate a proposed Six Sigma project. ! Recognize characteristics of a good project. ! Recognize characteristics of a bad project.

7 Map a business process. PROJECT

Describe the goal of process mapping. Identify the components of a process map (COPIS). Describe the steps involved in creating a process map. Define and name a process. Given a business process, use brainstorming and storyboarding techniques to:

identify its outputs, customers, suppliers, and inputs; identify customer requirements for primary outputs; and identify process steps.

8 Obtain approval for a Six Sigma project. PROJECT Identify the steps in the project approval process. Enter a project into QPT.

9 Describe the CAP tools and their connection to Six Sigma. TEST 3 QUESTIONS

Measure

1 Recall the DMAIC 12 Step process, and distinguish between characterization phases

(DMA) and optimization phases (IC). TEST 1 QUESTION Define product characterization. Define process optimization.

2 Recognize how statistics can be applied to the problem solving process. TEST 2

QUESTIONS Define the terms precision and accuracy as they relate to a Six Sigma

process. Relate precision/variation and accuracy/mean to quality and customer

satisfaction. State the goal of Six Sigma in statistical terms. Define the term Upper Specification Limit (USL). Define the term Lower Specification Limit (LSL). Define the term target (T). Define ".

3 Identify the project Y. PROJECT

Identify the tools that may be used to select the relevant CTQ or Y on which to focus.

Explain the purpose Quality Function Deployment, Process Map, and FMEA tools have.

Define performance standards for Y including specification limits as well as defect and opportunity definitions.

4 Explain how statistics can be used to solve problems. TEST 1 QUESTION Identify project variables using the formula Y = f (X1,..,Xn ). Describe the relationship between any dependent variable (Y) and

independent variables (X). Explain how the shape, mean, and standard deviation characterize a process. Express the capability of a process in terms of a standard measure (z-value). Define hidden factories and how capability impacts cycle time.

5 Identify the key deliverables of the Measure phase of DMAIC. TEST 1

QUESTION 6 Describe and define the deliverables of Step 1. TEST 1 QUESTION

7 Given a Six Sigma case study, characterize a product by applying concepts from Define, Measure, and the first step of Analyze. N/A

Select a CTQ characteristic. Identify X and Y variables. Use survey data to derive a performance standard. State a performance standard using descriptive statistics, including mean,

median, mode, mid-range, range, variance, and coefficient of variation, skew, and kurtosis.

Use Minitab to establish a process capability.

8 Select CTQ characteristics. PROJECT Select the Critical to Quality (CTQ) characteristic to be improved in a project. Narrow the focus of a project to an actionable level. Establish the project team and gained consensus on the project definition.

9 Relate and apply the Quality Function Deployment (QFD) process to Six Sigma.

TEST 1 QUESTION Explain the purpose of QFD. Describe the phases of QFD. Explain QFD flowdown for product and service applications. Generate/build a House of Quality (Product Planning Chart). ! Identify what the customer wants (the whats). ! Identify the functions or processes that impact customer wants (the hows). ! Evaluate the impact of each function/process on customer wants. ! Calculate the overall magnitude of the impact each function/process has on

customer wants (prioritize actions). Analyze and diagnose a completed House of Quality. Describe other QFD applications. Determine when QFD is appropriate to use. Recognize QFD pitfalls. Describe an example of QFD from GE Medical Systems.

10 Select and apply appropriate tools to narrow the focus of a Six Sigma project by

identifying key areas for improvement. PROJECT Identify tools that may be used to narrow the focus of a project, including

Process Map, and FMEA. Recognize the purpose and benefits of each tool.

11 Use Process Mapping to identify potential breakdowns, rework loops, and sources of

variation in a process. PROJECT Use the C.O.P.I.S. model to illustrate a customer focused process. Identify the elements of a process (input, mechanism, control, output, process

boundary). Identify and distinguish between internal and external process controls. Recognize the purpose and benefits of process mapping. Recognize the three types of process maps. Describe the process mapping process, including the following steps: ! Determine the scope. ! Determine the steps in the process. ! Arrange the steps in order. ! Recognize ISO 9000 standard symbols for process mapping. ! Validate a process map. ! Evaluate a process map.

12 Use a Failure Modes and Effects Analysis to identify the potential failure modes of a

process or product. PROJECT Recognize the purpose and benefits of FMEA. Describe how FEMA works. Describe FMEA, including preparation, process, and improvement steps. Define the terms failure mode, cause, and effect, as they relate to

FMEA, and recognize examples of each. Assign degree of severity, likelihood of occurrence, and ability to detect

ratings, and calculate a risk priority number (RPN). Complete an FMEA form. ! Recognize when and by whom an FMEA is prepared, updated, and completed.

13 Describe and define the deliverables of Step 2. TEST 1 QUESTION 14 Define Performance Standards for a Six Sigma project. TEST 3 QUESTIONS

Describe the purpose and characteristics of a performance standard. Describe the purpose and characteristics of an operational definition. Define the term defect. Given an example of a problem or process, write an operational definition. Describe and distinguish between continuous and discrete data. Recognize the components of a performance standard, including

product/process characteristic, measure, target value, specification limits, and defect.

Given a CTQ type, identify performance standard sources and discrete/continuous data measurement methods.

Given an example, define the measurable characteristic, determine whether it is continuous or discrete, determine the specification limit if applicable, identify a defect.

15 Describe and define the deliverables of Step 3. TEST 1 QUESTION 16 Establish a Data Collection Plan for a Six Sigma project. PROJECT

Describe the purpose and benefits of a Data Collection Plan. Write a data collection strategy. Define a clear strategy for collecting reliable data efficiently.

17 Establish the accuracy of the measurement system and the data (Analyze the

measurement system). TEST 4 QUESTIONS Describe measurement as a process that includes Measurement, Analysis,

Improvement, and Control phases. Describe measurement as a system that includes operators, gages, and

environment. Define the terms (gage) resolution, precision, accuracy, and bias as

used in Measurements System Analysis (MSA). Using the MSA checklist, document the existing measurement system. Recognize the sources of variation in a measurement system.

18 Conduct a test-retest study and analyze the results. TEST 1 QUESTION

Describe the purpose and procedure for conducting a test-retest study. Plot and test-retest study data. Use descriptive statistics to evaluate test-retest study data.

19 Conduct a Gage R&R study and analyze the results. TEST 2 QUESTIONS

Develop and implement a Data Collection Plan to collect Gage R&R study data.

Describe equipment and appraiser sources of variation. Describe the total R&R variation in terms of Reproducibility (AV) and

Repeatability (EV). Set up, collect, and enter data into a Minitab data sheet. Calculate both the appraiser variation (reproducibility) and equipment

variation (repeatability). Describe the concepts of stability and linearity in gage studies. Compare R&R variation to the tolerance (specification window). Create graphs and charts (ANOVA method) to analyze study results. Recall and apply rules of thumb (guidelines) for analyzing R&R study results.

20 Characterize the analysis of gage R & R results using the short form. CLASSROOM

Describe the short form and show an example of its use. 21 Describe and show the gage R & R stoplight and the rules of thumb.

TEST 1 QUESTION 22 Describe and define the use of gage R& R for discrete data. TEST 2 QUESTIONS

Describe the use of the attribute R & R spreadsheet for discrete data.

23 Describe the implications of calibration standards to gage R & R. TEST 1 QUESTION

24 Describe and show the use of gage R & R results in destructive testing.

TEST 1 QUESTION 25 Recall and list the deliverables of the Measure phase of DMAIC.

TEST 1 QUESTION

Analyze 1 Describe and define the deliverables of Step 4. TEST 1 QUESTION 2 Apply statistical principles of the Standard Normal Probability Distribution to

predict the probability of a defect and process capability. TEST 8 QUESTIONS

Use continuous data to describe a process by its average, standard deviation, and normal curve.

! Define the term random variable. ! Interpret uniform, triangular, normal, and exponential distributions. ! Relate probability to distribution curves. ! Define the terms mean and standard deviation as they relates to a normal

distribution curve. ! Recognize and distinguish between population and sample computational

equations. ! Use Minitab to calculate a mean and standard deviation. ! Recognize the Descriptive Statistics tool as a method for validating

calculations. Calculate statistical measures of variation, including range, deviation, sum-of-

square, standard deviation, and coefficient of variation. Calculate capability (Z value). Perform basic statistic calculations using Minitab. Describe the purpose and characteristics of Descriptive Statistics tools,

including Histogram, Dot Plot, Box and Whisker Plot, Run Chart. Be able to distinguish a normal distribution from other common non-normal

distributions.

3 Characterize a process using discrete data. TEST 2 QUESTIONS Define the terms unit (U), opportunity (OP), and defect (D). Recognize formulas for DPU, TOP, DPO, and DPMO. Use Z tables to convert DPMO to Z. Run and interpret a Minitab Product Report. Compare and contrast Classical Yield (Yc), Throughput Yield (YTP), and

Rolled Yield (YRT). Calculation the distribution of defects for a given DPU. Calculate submitted, observed, and escaping defect levels. Recall DPU application rules. Determine how DPU controls Throughput Yield (YTP). Explain how complexity impacts quality.

4 Use Process Centering strategies to perform a capabilities analysis. TEST 5 QUESTIONS

Explain the concept of Process Centering. Distinguish between special (assignable) and common (random) cause

variation. Choose rational subgroups for proper sampling and analysis. Differentiate between entitlement, short term process capability, and long

term process capability. Interpret Minitab hand calculations, histogram, and box plots. Calculate the long and short term standard deviation and Z-values. Explain the general long term 1.5 Z shift. Use Minitab Six Sigma Process Report to obtain short and long term process

capability measures - ZST, ZLT, ZbenchLT, Zshift, DPMOST, DPMOLT. Using capability measures and a 2x2 matrix, determine if there is a control

problem or a technology problem.

5 Determine process capability. TEST 3 QUESTIONS Define the term process entitlement as it relates to process capability. Define and provide examples of common cause and special cause variation. Define and use rational subgrouping of data. Define shift and drift of a process. Describe the components of variation. Calculate variation for a given process. Calculate the standard deviation for a process. Calculate process capability. Define the difference between long term and short term capability and their

uses in a six sigma project. Define the use of the sum of squares and the standard deviation. Use the universal equation for Z to calculate Z scores. Define, derive, and use the Z-Bench for a process. Relate and convert between the Z score and Defects per Million

Opportunities. Use data collected in the Measure phase to generate a process capability chart

for a process. Interpret the results generated by the process capability report to determine the

short term and long term process capability of a process. Use process capabilities to compare your process with a benchmark process. Determine whether the deficiencies in a process are due to control problems or

technology problems.

6 Describe and define the deliverables of Step 5. TEST 1 QUESTION

7 Use benchmarking to assist in developing project goals. PROJECT

Describe the purpose of benchmarking. Describe the uses of five different types of benchmarking, including

competitive benchmarking, product benchmarking, process benchmarking, best practices benchmarking, strategic benchmarking, and parameter benchmarking.

Apply benchmarking methodology to a variety of situations. List potential sources of benchmarking data and how to access such sources. Describe the advantages and disadvantages of Internal, Competitive, and

Functional benchmarking and their relationship to Best Practices.

8 Set realistic and achievable defect reduction goals based on current baseline, GE guidelines, benchmarking results, and the process entitlement. PROJECT

Describe the methods used to set project goals. Use GE Standards for defect reduction in combination with benchmark results

to determine project goals. Use the process entitlement to validate the achievability of the project goals.

9 Develop consensus within a project team on the acceptability of the project goals.

Use a Cause & Effect (Fishbone) diagram to identify Xs that may impact the Y that is important in a project and provide a visual display of all possible causes of a specific problem. PROJECT

Recognize the purpose and benefits of a Cause & Effect diagram. Write a problem statement. Brainstorm categories appropriate to a problem. ! Recognize the 4 Ps: policies, procedures, people, and plant. Brainstorm and analyze causes for each category to identify the most likely

cause(s) of a problem. Determine which causes need to be verified with data.

10 Use a Pareto Chart to separate the vital few from the trivial many in a process to

determine where to focus improvement efforts. TEST 1 QUESTION Recognize the purpose and benefits of a Pareto Chart. Describe the Pareto Principle. Describe the steps involved in building a Pareto Chart: ! Collect data. ! Total results and arrange data in descending order. ! Draw and label a Pareto Chart. ! Analyze results.

Compare before and after Pareto Chart to evaluate improvement effectiveness. 11 Describe process map analysis. PROJECT

Describe value added/ non-value added analysis.

12 Describe and define the deliverables of Step 6. TEST 1 QUESTION 13 Identify variation sources. TEST 3 QUESTIONS

Brainstorm a list of potential vital Xs. Use a histogram to aid in determining variation, center, and shape of a

process. Use a dot plot to aid in determining variation, center, and shape of a process. Use a box plot to aid in determining variation, center, and shape of a process. Use a run chart to determine process stability. Define the terms population and sample and relate the two to each other. Use statistical tests to validate sampling techniques. Define the theoretical framework for hypothesis testing. Define and follow the hypothesis testing protocol. Define the terms null hypothesis and alternative hypothesis. Develop the null hypothesis for your project. Develop the alternative hypothesis for your project. Define type I and type II errors in relation to hypothesis testing. Define the relationship between the confidence interval and the p-value.

14 Use the Statistical Analysis Roadmap to determine when it is appropriate to use specific tools in hypothesis testing. TEST 1 QUESTION These tools include:

Scatterplot Simple Regression Curve Fitting Logical Regression T-Test Homogeneity of Variance 1-way ANOVA Goodness of Fit Test of Independence Multiple Regression DOE 2 (or more)-way ANOVA Multiple Logistic Regression Multivariate Statistics

15 Perform hypothesis testing for a continuous Y and discrete X.

TEST 1 QUESTION Determine process stability with run charts and other tools Determine the data shape with histograms, normal probability plots, and

Anderson-Darling tests. Select and use the appropriate tool to determine the p-value. Determine whether or not to accept the null hypothesis or the alternative

hypothesis.

16 Describe the statistical analysis tools and process for normal/non-normal data. TEST 2 QUESTIONS Describe the use of the normality test. Describe the use of Moods median for non-normal data.

17 Perform hypothesis testing for a discrete Y and discrete X. TEST 1 QUESTION

Use chi-square testing to determine the goodness-of-fit and as a test of independence.

Based on the chi-square test, determine whether or not to accept the null hypothesis or the alternative hypothesis.

18 Perform hypothesis testing for a continuous Y and continuous X.

TEST 1 QUESTION Use a scatterplot to determine correlations between variables. Use a linear regression analysis to quantify correlations and predict values. Determine process stability with run charts and other tools. Determine whether or not to accept the null hypothesis or the alternative

hypothesis. Describe the use of multiple regression for this type of data. Describe the implications of multiple regression in statistical analysis.

19 Hypothesis Testing: Continuous Y; Continuous Xs and Discrete Xs. TEST 1 QUESTION Describe and define the general linear model. Describe and define messy data Provide and describe examples of messy data.

Improve 1 Describe and define the deliverables of Steps 7 and 8 in Six Sigma.

TEST 4 QUESTIONS 2 Characterize Xs as either operating parameters or critical elements. PROJECT

3 Develop a strategy for those Xs identified as operating parameters. PROJECT

Develop a mathematical model of a proposed solution. Determine the best configuration or combination of Xs

4 Develop a strategy for those Xs identified as critical elements. PROJECT

Optimize process flow issues. Standardize the process. Develop a practical solution. Explain the needs and process to do screening experiments. The implications

for this in DOE is described.

5 Define, detect, and determine the significance of lurking variables. PROJECT

6 Design and execute a full factorial screening Design of Experiments (DOE). TEST 4 QUESTIONS

Identify all factors. Select factor levels for the screening DOE. Use MiniTab to design a full factorial DOE, including randomization and

replication. Collect data. Use MiniTab to analyze the data. Interpret the results of a screening DOE, including main effects plots and

interaction plots. Verify results.

7 Perform optimizing experiments in order to develop a proposed solution.

TEST 2 QUESTIONS Identify factors for optimization experiments. Identify factor levels for optimizing experiments. Design optimizing experiment to include randomization and replication. Perform experiments and collect data. Analyze data with various tools including regression analysis.

8 Determine when a fractional factorial DOE is appropriate. TEST 2 QUESTIONS

Define the costs and benefits of using a fractional factorial design. Determine how to design a fractional factorial DOE to address critical factors. Define required trade-offs in a fractional factorial design. Describe the concept of resolution and its implications in DOE.

9 Develop a proposed solution. TEST 1 QUESTION

Interpret the outputs of various tools to determine the optimum solution. 10 Describe the experimenters checklist. CLASSROOM 11 Conduct a DOE for variances. PROJECT 12 Describe and define the deliverables of Step 9 in Six Sigma. TEST 1 QUESTION 13 Establish operating tolerances. TEST 4 QUESTIONS

Describe the concept of tolerances and describe an example of this concept. Describe the use of simulation and the use of Crystal Ball. Describe and show an example of Crystal Ball.

14 Pilot the proposed solution. PROJECT

Control 1 Describe and define the deliverables of Steps 10 and 11 in Six Sigma.

TEST 1 QUESTION 2 Describe and define the deliverables of Step 12 in Six Sigma. TEST 1 QUESTION 3 Develop/modify and implement Quality Plans. PROJECT

Describe the purpose and characteristics of a Quality Plan. Recognize the components of a Quality Plan. Plan ongoing process controls, including monitoring and auditing strategies. ! Explain the benefits of monitoring as compared to First Article Inspection

(FAI) and Information Management methods. ! Determine what to monitor for a given process. ! Determine the appropriate amount of monitoring data to collect, and how

frequently the monitoring should occur. ! Recognize methods for detecting changes in a process. ! Recognize the steps that should be taken if a process change is detected. ! Explain the purpose of auditing. ! Describe guidelines for effective auditing. Compare and contrast manufacturing control methods. ! Explain the purpose and process of variable data charting (SPC). ! Explain the purpose and process of process management charting.

4 Develop and implement risk management strategies. PROJECT

Explain the value of a risk management process. Define the terms risk and risk management as they relate to DMAIC/Six

Sigma. Determine when to use risk management. Recognize different types of risks. Recognize the steps involved in risk management, including identifying risks,

rating risks, abating risks, and executing risk management plans. Recognize methods for identifying risks. Describe methods and tools for rating risks. ! Using the Probability of Occurrence Rating guide and Consequence of

Occurrence/Risk Impact chart, prioritize risks according to risk factor score. Determine when and how to implement a Risk Abatement plan. Integrate lessons learned from prior risk management efforts. Describe the formal risk review process. Explain the criticality of tracking and executing risk abatement plans.

5 Develop and implement mistake proofing strategies. PROJECT Recognize examples of mistake proofing. Describe principles underlying the process of mistake proofing. Recognize the difference between errors and defects. Explain how defects originate. ! Identify ten types of human error. ! Recognize human error-provoking conditions. Identify the three key mistake proofing techniques: shutdown, control, and

warning. Distinguish between prediction/prevention and detection methods of mistake

proofing. Recognize typical mistake proofing tools. Describe the 5 steps involved in mistake proofing, including identifying

problems, prioritizing problems, finding the root cause, creating solutions, and measuring results.

Recognize the advantages of mistake proofing as a proactive tool. Explain how mistake proofing fits into the Six Sigma process.

6 Develop and implement Variable Control Charts. TEST 4 QUESTIONS

Describe the purpose of Statistical Process Control Charts. Given a control chart, recognize when a special cause is acting on a process. Recognize other types of variable control charts, including X Bar Chart, R

Chart, Individuals Chart, and Moving Range Chart. State the five main uses of control charts. Describe data collection and sampling techniques. Establish and maintain control limits. Select the appropriate Variable Control Chart. Distinguish between control limits and specification limits. Determine whether a process is in control or out of control. ! Recognize Western Electric rules for identifying an out of control process. Recognize and apply Minitab rules. Build an Individuals and Moving Range chart. Use knowledge of the process to eliminate or reduce assignable/special

causes.

7 Develop and implement Attribute Control Charts. TEST 2 QUESTIONS Describe the purpose of Attribute Control Charts. Define and relate the terms a defect and a defective. Recognize types of Attribute Control Charts, including C-Charts, U-Charts, P-

Charts, NP Charts. Select the appropriate Attribute Control Chart. Use Minitab to generate each type of Attribute Control Chart. Determine the appropriate Attribute Chart subgroup size.

8 Select and apply the appropriate Control Chart. TEST 2 QUESTIONS Recall and explain SPC Concepts, including controlled variation, uncontrolled

variation, common causes, and special causes. Recognize the five main uses of control charts. Distinguish between variable, attribute, and process focused control charts. Determine control limits. Distinguish between control limits and specification limits. Recognize the four states of a process.

Glossary and Minitab Primer

1 Define the typical terms used in Six Sigma methodologies. 2 Describe the use of the Minitab software program.