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1、1Six Sigma DeploymentChampion Training1Six Sigma Champion Training Key QuestionsWhat is a Black Belt and their roles and responsibilities?What is a Master Black Belt and their roles and responsibilities?What is a Green Belt and their roles and responsibilities?What are the roles and responsibilities
2、 of senior&line management?What does a Six Sigma deployment Roadmap look like and what are its key features?What resources must be effectively allocated in order to effectively deploy Six Sigma?What metrics should be used to monitor the deployment of Six Sigma?2Six Sigma Champion Training Why Six Si
3、gma&Why Now?Recognize the urgency for changeDifferent from past Quality ProgramsFinancial focus gains Executive SupportBusiness measurements changeRole of Finance changesProjects are monitored to closureImprovements are institutionalizedResults in demonstrated successAbility to compete improves 3Six
4、 Sigma Champion Training Senior Management Ownership is KeyLink Six Sigma to the business strategyCreate the vision for the organizationSet stretch goals and metrics to focus effort on Six Sigma QualitySelect the Best People with the right structureAsk questions that generate new thinking on Quality
5、 and Productivity4Six Sigma Champion Training How does Six Sigma WorkSenior Management establishes vision,challenge and objectivesChampions/Process Leaders provide focus,leadership and commitmentDedicated resources(Master Black Belts/Black Belts)lead and perform improvement effortsProjects focus on
6、customer(CTQs)satisfaction and real business problemsProcess selects key improvement projects,tracks and quantifies resultsDedicated resources(Project Teams)deploy and their functional organizations5Six Sigma Champion Training Six Sigma Deployment PlanVision and Business PlanMetrics,Goals and Object
7、ivesRoles,Responsibilities and StructureMaster Black Belt/Black Belt Selection ProcessReward and Recognition ProcessTraining,Evaluation and Certification ProcessesData Collection and Analysis SystemProject Selection and Review ProcessProject Back-log ListSix Sigma Reporting ProcessCommunication Proc
8、ess6Six Sigma Champion Training Quality and Customer Satisfaction New Product Innovation Process Capability and Cycle Time Cost ReductionProcess Cost Savings focusProject Quality focusProduct focus(Six Sigma Design)Problem focus(Worst Way)Ways to Focus ProjectsBusiness Priorities must Focus Six Sigm
9、a Efforts7Six Sigma Champion Training SeniorManagementLineManagementProject Teams&Green BeltsChampionsMasterBlack BeltsBlack BeltsororSix Sigma Organization Structure8Six Sigma Champion Training Champion -One per Company to implement Six Sigma for 2 years -Site Leaders become Champions after 2 years
10、Master Black Belts -One to Three depending on Company sizeBlack Belts -One to Three per site depending on sizeGreen Belts -30 to 40%of work force after 3 yearsSix Sigma Organization Guidelines9Six Sigma Champion Training All employeesMaster BlackBelts Black BeltsGreen BeltsProject TeamMembers LineMa
11、nagement Part time Project specific knowledge Help Hold the Gains Part time Help Black Belts Help Line management Hold the Gains Full time Facilitates problem solving Trains&coaches Project Teams Full time Trains&coaches Black Belts Understands vision Applies concepts to their jobs and work area Own
12、s process Implements solutions Leads Six Sigma change Owns vision,direction integration,results Leads changeExecutive Mgm.ChampionSix Sigma Roles and Responsibilities10Six Sigma Champion Training 0102030405060708090100ProjectTeamMemberBlack BeltMasterBlack BeltChampion Green BeltSeniorManagement Lin
13、eManagementPercent of Time Allocated to Six Sigma Activities11Six Sigma Champion Training Initial Executive ResponsibilitiesEstablish Corporate CommitmentSet the challenge to achieve 6s Process PerformanceChoose high-potential people to become Champions,Master Black Belts and Black BeltsSupport 6s T
14、raining and Project ReviewsEstablish 6s Project Selection Process,Business Scorecard and Reporting ProcessAssure integration of 6s in all aspects of the businessIntegrate into the Business Planning ProcessReward and RecognitionHuman Resource PracticesConsistent Measurement12Six Sigma Champion Traini
15、ng Ongoing Executive Responsibilities Require all presentations use data including the Mean and Variation Ask for an explanation of the causes for variation Challenge the organization to achieve World Class performance (6s s)and process capability(Cpk2)Encourage Statistical Thinking Recognize and Re
16、ward accomplishments Distribute Best Practices Drive Project Selection Process as part of Business PlanningContinually energize the Six Sigma Process13Six Sigma Champion Training The Role of a Champion Manage deployment,implementation and reporting Create the Vision and Define the Path to implement
17、Six Sigma across the business(Roadmap)Acquire and utilize practical statistical knowledge Identify&Certify Black Belt candidates Drive project selection process Influence Peers in the application of Six Sigma Realize the Gains by supporting Six Sigma project teams and remove the roadblocks to their
18、success Hold the Gains by implementing recommendations Recognize Project Teams for their efforts Coach and Mentor Black Belts and Master Black Belts14Six Sigma Champion Training Work in conjunction with the Master Black Belts to mobilize commitment and make change lastHow Champions help Accelerate t
19、he Change Process?Use Six Sigma as a management operating philosophyTear Down Road Blocks to the Six Sigma ProcessEnsure“Process Owners”Support and Project OwnershipAsk Black Belts many Questions to Ensure that they are Focused AppropriatelyApply lessons learned from Six Sigma implementation Encoura
20、ge Follow-up&Monitoring Activities to Sustain ResultsTransition learnings to other projects/processesReport Six Sigma financial and performance resultsMonitor Projects,Executive Reviews and Recognition Program15Six Sigma Champion Training.CHANGING THE CULTUREThe Role of a Master Black BeltMentor and
21、 coach Black Belts&Green BeltsAdvise Senior Management in driving the Six Sigma culture into the organizationLead cross-functional teams in resolving critical problemsDevelop and teach Six Sigma Black Belt training Provide technical statistical and Six Sigma expertiseMonitor Black Belts efforts on p
22、rojectsNetwork with other Six Sigma organizationsAssure the rigor and discipline of the Six Sigma methodology is used on projects16Six Sigma Champion Training Apply Six Sigma methods on projects&achieve improvementsServe as change agent and tool mentor in implementing 6s sAssuring the rigor and disc
23、ipline of the Six Sigma methodology is used on projectsEnsuring that the improved process Stays improvedProvide feedback to the Champion on project progress/results Mentor,coach and teach process leaders,work teams and Green Belts in defect reduction and Six Sigma methodsAssure reporting of project
24、status and Six Sigma metrics.CHANGING THE CULTUREThe Role of a Black Belt17Six Sigma Champion Training Black Belt Candidate SkillsCritical SkillsStrong desire to learnComputer literateAbility to lead a team and teachProblem solving skillsInterpersonal skills to influence peopleDesire to be a Black B
25、eltStrong communication and presentation skillsSupporting SkillsA background in basic mathematics and statisticsKnowledge of processesWilling to give and accept constructive feedback 18Six Sigma Champion Training A Black Belt must:Want to do it Learn the methods and tools Be willing to practice Be a
26、llowed to practice Have adequate resources Have adequate coachingBlack Belt Candidate19Six Sigma Champion Training Improved Process Capabilities Increased Yields Reduced Defects Reduced Cycle time Increased Capacity Increased Employee Pride,Confidence in Leadership,and Customer Satisfaction$SAVINGS$
27、The Results of Black Belt Efforts20Six Sigma Champion Training Typical project requires 4-6 months to complete with annual savings of$100,000 Black Belts complete 6-8 projects annually Annual savings per Black Belt exceeds$500,000$SAVINGS$Expectations of Black Belt Efforts21Six Sigma Champion Traini
28、ng MEASUREANALYZEIMPROVECONTROLBlack BeltsWork Team 100%INVOLVEMENTTIME0%Black Belt and Work Team Involvement/Ownership22Six Sigma Champion Training Senior Management-1 Day -Ensure Senior Management buy-in and understandingChampions&Master Black Belts-2 Days -Establish infrastructure and understandi
29、ng Line Management-1 Day -Establish Line Management support and understandingBlack Belts-20 Days -Create full time Black Belt resourcesGreen Belts-7 Days -Create part time resources to leverage the Black BeltsProject Team Members-1 Day -Create project specific support for the Black Belts Six Sigma T
30、raining must flow top-downSix Sigma Training 23Six Sigma Champion Training Copyright 1995 Six Sigma Academy,Inc.PlanTrainApplyReview PlanProject Planning TrainFormal Training ApplyProject Application ReviewProject Presentation Completed for each of the 4 Phases Training Strategy Leads to Six Sigma B
31、lack Belt Certification24Six Sigma Champion Training Month 1Month 2Month 3Month 43 WeeksMeasureApplication3 WeeksAnalyzeApplication3 WeeksImproveApplication3 WeeksControlApplicationWeek 1MeasureTrainingWeek 2AnalyzeTrainingWeek 3ImproveTrainingWeek 4ControlTraining4 Master Black Belt&Champion Projec
32、t ReviewsFinal Project Report due at the end of Month 5Black Belt Training Deployment25Six Sigma Champion Training Monday Introductions Customer Focus Six Sigma Fundamentals The Breakthrough Strategy Project ReviewsTuesday Process Mapping Failure Mode&Effects Analysis Minitab OverviewWednesday Basic
33、 Statistics Capability AnalysisThursday Measurement System Analysis Project Planning/Deliverables&Project Reporting Friday Certification Requirements Black Belt Project Planning Reviews Week 1 Training Agenda26Six Sigma Champion Training Monday Project Review Week 1 ReviewTuesday Graphical Analysis
34、Multi-Vari Analysis Central Limit Theorem Confidence IntervalsWednesday Hypothesis TestingThursday Sample Size Selection Correlation/Regression Project Planning/Deliverables Certification RequirementsFriday Six Sigma Stats Project Planning Reviews Week 2 Training Agenda27Six Sigma Champion Training
35、Monday One Way ANOVA Randomized Blocks Project Reviews Tuesday DOE Planning Full Factorial Experiments 2-k Factorial Experiments Wednesday Fractional Factorial Experiments Catapult Workshop#1Thursday DOE Review Catapult Workshop#2 Project Planning/Deliverables Certification RequirementsFriday Naviga
36、tor Factory Simulator Project Planning Reviews Week 3 Training Agenda28Six Sigma Champion Training Monday Response Surface Methodology EVOP Project ReviewsTuesday Statistical Process Control ISO-9000/Six Sigma Synergy Kaizen&Lean Production Mistake ProofingWednesday Preventative Maintenance Statisti
37、cal Problem Solving Non-Normal Data AnalysisThursday Statistical Tolerancing Six Sigma Design Final Report ReviewFriday Navigator Factory Simulator Review Project Planning ReviewsWeek 4 Training Agenda29Six Sigma Champion Training.A1.In a nutshell,the Core Requirements are as follows:Completion of t
38、he BB training course(4 weeks)Successful BB Project Completion (goal achievement and documentation)Demonstration of Key BB ToolsFacts Regarding the Path to Become a Certified Black BeltQ1.What are the key requirements to get certified as a Black Belt?30Six Sigma Champion Training.A2.Quantification o
39、f achievement of Project Goals.For example,a statistically significant shift in the PPM chart indicating a 75%downward shift in the mean PPM level Completion of the steps to“Hold the Gains”Final Report completedFacts Regarding the Path to Become a Certified Black BeltQ2.What constitutes successful P
40、roject Completion?31Six Sigma Champion Training.A3.As a minimum,successful application of the following Key Tools on your project:Process Map,Process FMEA,Cause&Effect Diagram/Matrix,Gage R&R,Multi-level Pareto,Multi-Vari Chart,Hypothesis Test&DOE If you can not demonstrate these tools within your P
41、roject,you must agree to another vehicle for demonstration with your Master Black BeltFacts Regarding the Path to Become a Certified Black BeltQ3.What constitutes successful demonstration of Black Belt tools?32Six Sigma Champion Training.A4.Your Project Presentation in Week 4 should contain data to
42、verify that your Project Goals are being achieved on Target The Final report is due 4 weeks after Week 4 Training is completed.After your Project is approved by your Champion and Master Black Belt,your name will be submitted to ASQ for your Certification PlaqueFacts Regarding the Path to Become a Ce
43、rtified Black BeltQ4.What are the Key Timing Dates regarding Certification?33Six Sigma Champion Training.A5.You will receive a“Certificate of Completion”after successfully finishing the four weeks of training from ASQ:In order to receive your Six Sigma Black Belt certification,your sponsor must subm
44、it a signed copy of the Sponsor Evaluation Form to ASQ.Your Master Black Belt will use this form to approve your certification with ASQ after approving your Project based upon the Final Report Upon approval by the Master Black Belt,you will be awarded a Laser-Engraved Plaque by ASQ,which attests to
45、your certification Facts Regarding the Path to Become a Certified Black BeltQ5.What documentation will I receive?34Six Sigma Champion Training Plant Productivity Improvement Project List for Six Sigma,LM&VA(complete/active/backlog)Six Sigma Performance Detail Report Plant COPQ Report Product family
46、PPM chart Results Tool scorecard chart Solutions/Results charts for Black Belt,Lean&Value Analysis projects Customer Quality PPM chart Supplier Quality/Delivery charts Main customer and supplier issues documented on solutions/results chartSix Sigma Reporting35Six Sigma Champion Training Plant Produc
47、tivity Improvement Project List36Six Sigma Champion Training Six Sigma Performance Detail Report37Six Sigma Champion Training Plant COPQ Report38Six Sigma Champion Training Plant PPM Report39Six Sigma Champion Training Results Tool Scorecard Chart40Six Sigma Champion Training Solutions/Results Proje
48、ct Report41Six Sigma Champion Training Solutions/Results Project Report42Six Sigma Champion Training Customer Quality PPM Chart43Six Sigma Champion Training 44Six Sigma Champion Training Supplier Solutions/Results Chart45Six Sigma Champion Training Company PPM Report46Six Sigma Champion Training Com
49、pany COPQ Savings Report47Six Sigma Champion Training Company COPQ Savings Report48Six Sigma Champion Training Company COPQ Report49Six Sigma Champion Training Managing the Six Sigma Process in a Manufacturing Plant50Six Sigma Champion Training Select the Right Project51Six Sigma Champion Training Select and Train the Right People52Six Sigma Champion Training Develop and Implement the Six Sigma Process Improvement Plan53Six Sigma Champion Training Manage Six Sigma System for the Right Business Performance54Six Sigma Champion Training