Course Outline
Module 1 – Lean Six Sigma Foundations & MBB Role
- Evolution of Lean and Six Sigma
- DMAIC and DMADV overview
- Roles & responsibilities of Yellow Belt, Green Belt, Black Belt, and Master Black Belt
- Master Black Belt competencies and leadership expectations
- Project selection and prioritization at enterprise level
Module 2 – Organizational Strategy & Deployment
- Lean Six Sigma deployment models
- Linking projects to business strategy and KPIs
- Hoshin Kanri (policy deployment)
- Change management and stakeholder alignment
- Building a culture of continuous improvement
Module 3 – Advanced Define Phase Tools
- Voice of Customer (VOC) and Critical-to-Quality (CTQ) flowdown
- Advanced SIPOC and value stream scoping
- Project chartering at program level
- Risk identification and mitigation planning
- Financial validation and benefits realization
Module 4 – Advanced Measure Phase & Data Analytics
- Measurement system analysis (advanced MSA)
- Sampling strategies and data integrity
- Descriptive and inferential statistics
- Process capability analysis (advanced)
- Data-driven decision-making frameworks
Module 5 – Advanced Analyze Phase Techniques
- Hypothesis testing and regression analysis
- Design of Experiments (DOE) – full and fractional factorial
- Multivariate analysis
- Root cause analysis at system level
- Lean waste identification and bottleneck analysis
Module 6 – Improve Phase – Optimization & Innovation
- Solution generation and prioritization techniques
- Lean tools: Kaizen, SMED, Poka-Yoke, 5S
- Process optimization and simulation
- Change implementation planning
- Risk assessment using FMEA
Module 7 – Control Phase & Sustainability
- Control plan development
- Statistical Process Control (SPC) – advanced charts
- Visual management and dashboards
- Standardization and documentation
- Benefits tracking and sustainment strategies
Module 8 – Coaching, Mentoring & Program Governance
- Coaching Black Belts and Green Belts
- Reviewing and approving projects
- Governance structures and tollgate reviews
- Conflict resolution and leadership influence
- Ethics and professional conduct
Module 9 – Enterprise Integration & Continuous Improvement
- Integrating Lean Six Sigma with Agile, TPM, and digital transformation
- Scaling improvements across the organization
- Knowledge management and best practices
- Benchmarking and maturity assessments
- Building a long-term continuous improvement roadmap
