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is Six Sigma?
Six Sigma is a rigorous and disciplined methodology that uses
data and statistical analysis to measure and improve a company's operational
performance by identifying and eliminating "defects" in manufacturing and
service-related processes. Commonly defined as 3.4 defects per million
opportunities. Six Sigma can be defined and understood at three distinct levels:
metric, methodology and philosophy.
Six Sigma is a customer focused, data driven methodology for achieving real
break through success in business. Six Sigma is a comprehensive and flexible
system and can be applied to reduce defects, improve designs and process
Performance Level (99.73%)
is not enough?
A three Sigma level company is
not good enough, because a 3Sigma level performance means,
* 200,00 lost articles of mail per hour.
* No electricity for almost 7 hours, each month.
* 2 short or long landings at major airports, each day.
* 200,000 wrong drug prescriptions each year.
* Unsafe drinking water almost 15 minutes each day.
* 5000 wrong surgical operations per week.
(The above information is based on a survey conducted in US.)
Now, can anyone afford to stop at 3Sigma level performance?
If a company performs even at 3Sigma level, (that is 99.73% result fall with in
the control limits) the above defects are possible. Because of the above cited
huge loses, generally many companies go for Six Sigma Implementation
need to do Six Sigma?
Six Sigma can cut waste and save money. Consider how much money could be
saved by eliminating potential defects and the resulting scrap and warranty
returns. Time and money may be wasted in corrective actions and delays. Also
consider the image those results from product failures for the customer. In
order to determine the waste, you need to understand what adds value to your
product and what does not.
One way to know how good you are doing is to compare your operation to similar
ones elsewhere, as a benchmark. If there are similar operations in your
organization, then bench marking will be easier.
Six Sigma Costs and Savings:
One cannot expect to significantly reduce costs and
increase sales using Six Sigma without investing in training, organizational
infrastructure and culture evolution. It is sure you can reduce costs and
increase sales in a localized area of a business using the Six Sigma quality
methodology. For Example,
"Motorola adopted Six Sigma in1987. In 1988, Motorola
won its first Baldridge Award."
"Companies of all types and sizes are in the midst of a
quality revolution. GE saved $12 billion over five years and
added $1 to its earnings per share. Honeywell
(AlliedSignal) recorded more than $800 million in savings."
"GE produces annual benefits of over $2.5 billion
across the organization from Six Sigma."
"Motorola reduced manufacturing costs by $1.4 billion
"Six Sigma reportedly saved Motorola $15 billion over
the last 11 years."
CEOs, Presidents, Project Managers, Team
leaders/Members, Field Staff Members, Project Engineers, Design Engineers,
Project Leaders and Administrators, Industrial Engineers, Program Managers,
Manufacturing Engineers, Project Coordinators, Operating Managers, Functional
Managers, Information Technology Professionals, Software Developers, Quality &
Testing Engineers, Sales & Marketing professionals, Civil/Mechanical/Electrical
engineers, Procurement specialists, Event mangers, R&D Managers, others involved
directly or indirectly with Project Management, Quality assurance managers, BPO
team leaders, and Executive leadership from Finance, Training, Communications,
Human Resources and Quality who are interested in gaining a better understanding
of manufacturing processes and reducing process variability in order to improve
* Individuals who desire to enhance their professional
development with the skills necessary to support Six
* Employees of companies that have deployed Six
Sigma, who work with Black Belts, or who lead their own
improvement projects. Companies that
want to expand training across a wide range of employees to reduce
costs and improve performance.
Course Structure (Classroom):
This Lean Six Sigma Black Belt Workshop is a PMI approved Classroom study.
* All classroom participants who are PMPs will earn 40 PDUs
Certificate towards their CCR on the 5th day through
this PMI approved PDU course.
* Minitab, industry standard statistical software, will
be used to demonstrate and apply to many six sigma
problems throughout the course. This will
be a very useful deliverable for later applications and six sigma
* All classroom participants will be given a CD of full Black
Belt editable project template for their use. The CD
contains DMAIC stages, simple explanations,
some situational case studies, useful templates and Statistics
Software. This software useful to calculate
sigma levels and to draw Excel charts.
Creating Control Charts Using Microsoft Excel
Editable Project Charter
Editable SIPOC Diagram
Sample Size Calculator
Sigma Conversion Table
Six Sigma Sample Questions
Six Sigma Sample Project Report
Salient features of LSSBB
* Hypothesis Testing Additional practical examples
* Statistical process control Details
* Sample size calculations
* DOE (Design of Experiments) in detail with a
* Measurement System Analysis Gage R&R studies
* Learn how to deal with non-normal data
* Hands on practice on Minitab software
* There are excellent career growth opportunities for
Black Belts which span across functions and industries
Click here to see current training schedule.
* 5 Continuous days 9.00 AM 6.00 PM (OR)
* 1 week day & 2 Week-ends (Sat / Sundays) 9.00 AM 6.00 PM
Course fee for Lean Six Sigma
Certification - CLASS ROOM:
* Black Belt Certificate Only - Rs. 27,500 + 18% tax.
(for general professionals)
To See a Sample Certificate.
* Black Belt Certificate + 40 PDUs Certificate - Rs. 27,500 +
18% tax. only (optional item for PMPs only)
To See a Sample PDUs Certificate.
Earn 40 PDUs (PMI Approved) - Click here to see PMI
Lean Six Sigma
An open book paper based exam will be conducted on the final
day of the course. The exam is conducted to measure the knowledge gained by the
participants and to demonstrate the added confidence level out of this course.
Candidates have to secure 50% of marks to issue the Lean Six Sigma BLACK BELT
Please note that the projects for improvement can
be from your own company (or) any other company. The projects can address the
entire company are small portion (or) part (or) division (or) a small process of
a business unit within the company. The candidates can also suggest project
titles from their company for the faculty / instructors / suggestions (or) they
can choose any one of the projects available at IIPM. IIPM will facilitate the
collection of data and extend support staff services for the project period.
Lean Six Sigma Projects
Guided by IIPM:
1. Case management in Microsoft, Sutherland
A Case study - BPO Industry.
2. Reducing Turn Around Time (TAT) of Production
Support Request in Cambridge Solution A Case
3. Reduction of OLA Deviation in CVS processing
in SIFY A Case study - Software Industry.
4. Reduction in Manufacturing of Flanges
Production Turn Around Time (TAT)-A Case study-
Some example projects are
1) Registration process improvement.
2) Defects and improvements in Training.
3) Defects and improvement in online training.
4) Customer Call registration Improvement.
5) Training course-ware quality improvement.
6) Admin and maintenance expenses improvement.
7) MARKETING EXPENSES IMPROVEMENT: RETURN ON INVESTMENT
The participants can identify projects in their own
organization and implement the DMAIC methodology and show significant
improvement in organization. The Students shall review the projects with IIPM on
monthly basis. Any questions clarifications can be discussed during the review.
Sample project is available for all
Online/Classroom registered participants.
Practical Hands-on Six
The following practical hands-on experiments will be
conducted and guided by Mr. Ari to reinforce the theoretical learning into
practical application of six sigma concepts.
1) Mistake proofing (Poke Yoke)
2) Design of Experiments (DOE)
3) Construction of Normal/Binomial Probability
curve using a game of chance
4) Accuracy Vs Precision
6) Reproducibility & Repeatability (Gage R&R)
7) Failure Mode & Effects Analysis (FMEA)
Recent job opportunities for Lean Six Sigma Green
Lean SIX SIGMA BLACK BELT
CLASS ROOM COURSE CONTENTS
DAY 1: DEFINE PHASE
Understanding Six Sigma
- Problem Solving
- Roles & Responsibilities
Up & Action Items
DAY 2: MEASURE
STAGE [26 Questions]
- Cause & Effect Diagrams
- Detailed Process Mapping
Six Sigma Statistics
- Basic Statistics
- Descriptive Statistics
- Normal Distribution
- Assessing Normality
- Special Cause / Common Cause
- Graphing Techniques
Measurement System analysis
- Basics of MSA
- Variables MSA
- Attribute MSA
- Continuous Capability
- Concept of Stability
- Attribute Capability
DAY 3: ANALYZE
STAGE [24 Questions]
- Multi-Variate Analysis
- Classes and causes
- Nature of Sampling
- Central Limit Theorem
Introduction to Hypothesis Testing
- Purpose of Hypothesis Testing
- Tests for Central Tendency
- Tests for variance
Hypothesis Testing ND P1
- Sample Size
- Testing Means
- Analyzing Results
Hypothesis Testing ND P2
Hypothesis Testing NND P1
- Equal Variance Tests
- Tests for Medians
Hypothesis Testing NND P2
DAY 4: IMPROVE STAGE
Process Modeling: Regression
- Introduction to Regression
- Simple Linear Regression
Design of Experiments
- Reasons for Experiments
- Graphical Analysis
- DOE Methodology
Full Factorial Experiments
- Mathematical Models
- Balance and Orthogonality
- Fit and Diagnose Model
- Center Points
Fractional Factorial Experiments
- Confounding & Resolution
CONTROL STAGE [21 Questions]
- Vision of Lean Supporting Six Sigma
- Lean Tool Highlights
- Project Sustained Success
- Realistic Tolerance and Six Sigma Design
- Process Automation or Interruption
Statistical Process Control (SPC)
- Elements and Purpose
- Special Cause Tests
Six Sigma Control Plans
- Solution Selection
- Control Plan Elements
Final Six Sigma Exam Open book / Group Test
Six Sigma CD Demo