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Babcock Training Academy

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Lean Six Sigma (LSS) Black Belt Program - Week 1 & 2

Course Description

This 4-week hands-on workshop with Dr Mark Kiemele provides participants with the detailed methodology and tools of Lean Six Sigma to lead their organization toward “World Class” status. The workshop combines the proven and powerful elements of both traditional Lean and traditional Six Sigma into a blended approach. The emphasis is on 1) gaining process and product knowledge with critical thinking 2) reducing variability and non-value added activities and 3) developing leaders in the organization who are focused on enhancing customer value, decreasing defect rates and wasted efforts, reducing cost and cycle time, and generating business growth and breakthrough improvements. The Lean Six Sigma methodology is taught with a “Keep It Simple Statistically” (KISS) approach and makes use of many in-class examples, simulations, and hands-on exercises to ensure that participants have a practical, working knowledge of the tools.

Participants in the Lean Six Sigma Black Belt Training learn the details of the Define, Measure, Analyze, Improve and Control (DMAIC) methodology and tools for achieving better, faster, and lower cost products and processes. We use a knowledge-based approach to “pull” the use of Lean and Six Sigma tools, not push them. Participants learn to select and apply the right tools for a particular problem or question.

As a part of the course, it is expected that participants come with a project to work on so that they can immediately apply their knowledge and realize return on investment on a specific business issue. These first two weeks of the LSS Black Belt program constitute a LSS Green Belt program. If the student wants to go on to LSS Black Belt certification, then Weeks 3 and 4 must also be taken.

Our Lean Six Sigma Black Belt Training uses the “Present/Practice/Apply/Review” strategy. That is, we present tools and methods, give participants the opportunity to practice them in class, and then apply the tools to their project, and finally review the results of the application to the projects.

Target Audience

The intended audience is anyone who desires to become a practitioner of the Lean Six Sigma methodology and tool set and who will be leading Lean Six Sigma projects within an organization.

Participants are expected to have management sponsorship and a project selected prior to attending the training. Projects will be worked on over the duration of the course and should be completed within a reasonable timeframe, typically near the end of the training but no longer than 6 months after the start of the training.

Participants are strongly encouraged to bring a laptop computer to class with Excel 2000(or above) so that they can install the supplied software and practice using it during many in-class exercises. A basic working knowledge of Windows and Excel is helpful. Basic math and algebra skills are also desirable.

Course Outline

Week 1:

Lean Six Sigma: The Journey Begins

The What and Why of Lean Six Sigma Key Elements and Infrastructure Roles and Responsibilities
Lean Six Sigma Project Master Strategy Factors Critical to the Implementation of Lean Six Sigma
Importance of Knowledge and the Role of Questions

Lean Six Sigma Fundamentals

Core Lean Six Sigma Principles Concepts of Value and Value Stream
Defining Processes Using IPO Diagrams
Key Terminology (Distribution, Mean, Median, Standard Deviation, Cp, Cpk, sigma level, first pass yield, defects)
PF/CE/CNX/SOP (the first line of defense against variation)
Measuring and Understanding the Cost of Poor Quality/Cost of Waste

Defining the Project and Managing Change

Elements of the Define Phase of DMAIC Selecting and Defining a Lean Six Sigma Project
Elements of the Project Charter Problem Statements, Project Goals, and Measures
Stakeholder Analysis Importance of Good Project Management Teamwork
Understanding Change and Ingredients for Successful Change

Understanding the Voice of the Customer (VOC) and Defining a Process

Understanding the Voice of the Customer Managing the Customer Experience Kano’s Model
Introduction to Quality Function Deployment (QFD) Building a Simple House of Quality
Creating a High Level Process Map using a SIPOC Diagram

Measure…Making Sense out of Data using Graphical and Measurement Tools

Detailed Process Mapping (process flow, simple value stream maps, spaghetti diagrams, time value maps)
Planning for Data Collection Graphical Analysis of Data Pareto charts Histograms Box plots
Run charts Scatter diagrams Numerical measures Measures of Location and Dispersion
Measures of Quality for Variables Data Measures of Quality for Attribute Data Measuring Correlation
Using SPC XL software and Interpreting Output

Measurement System Analysis

Properties of a Good Measurement System Impact of Measurement System Variation
How to Set Up, Conduct, and Perform a Measurement System Analysis Variables Data Attribute Data
Interpretation of MSA Results and Metrics Repeatability Reproducibility P/Tol ratio
Discrimination (resolution) Effectiveness, Probability of False Rejects, Probability of False Accepts

Week 2:

Analyzing the Causes of Poor Performance

Techniques for Identifying Potential Causes of Variation
Identifying Waste and the Seven Classic Types of Waste Evaluating the Cost of Poor Quality
Value and Non-Value Added Activities Analyzing Work Takt time Cycle Time Operator Loading

Techniques for Narrowing the Focus

Data Collection and Sampling Considerations
Confidence Intervals and Sample Size Calculations using SPC XL software
Techniques for Narrowing the Focus when Data is Limited Voting Nominal Group Technique
Effort / Impact Analysis Pairwise Comparisons Prioritization matrix Five Why's

Drawing Conclusions From Sampled Data

Elements of the Analyze and Improve Phases of DMAIC
Using Hypothesis Tests for Comparing Data Sets How to Conduct and Interpret Hypothesis Tests
How to Apply rules of Thumb (ROT) When Comparing Data Sets Using SPC XL for Hypothesis Testing

Improving the Process and Work Flow

Elements of the Improve Phase of DMAIC Reducing Setup and Changeover Times using SMED
Comparison of Batch vs. Single Piece Flow Cellular Manufacturing and Principles of Cell Design / Layout
Applying the Principles to Improve a Simulated Process
Mistake Proofing the Process Using FMEA and Error-Proofing (Poka Yoke)

Lean Six Sigma Mini-Project: Applying the Tools

Simulate A Process
Evaluate the Current State, Collect Baseline Data, and Identify Opportunities for Improvement
Make Improvements to the Process Simulate the Improved Process and Measure Results

Controlling Process Performance / Realizing and Holding the Gains

Basic Concepts of Statistical Process Control (SPC)
Difference Between Process Control and Process Capability
Construction, Interpretation, and Application of Control Charts Types of Charts Control Limits
Out of Control Symptoms Subgrouping Strategy Elements of an Effective Control Strategy
Visual Control and 5S for Workplace Organization Project Documentation

DMAIC Summary – Putting it All Together

Review of the Lean Six Sigma Master Strategy and Key Principles
DMAIC Phase Tollgates and Completion Checklists Building a DMAIC Tools Memory Jogger

Course Details

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Please register your interest in this course by contacting Babcock on +61 (0)8 8440 1498

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