Design for Six Sigma – Black Belt
Six Sigma Black Belt training
Design for Six Sigma (DFSS) Black Belt is a training in the Six Sigma methodology. It’s a customer-, fact-, and data-based approach to improving an organisation’s quality.
The DFSS Black Belt training provides you with new tools and competencies that you can utilise in your daily work. You become a sought-after employee, capable of achieving measurable results for your business. You can lead DFSS development projects based on the IDOV model, and possess a mindset that enables you to make well-considered decisions grounded in valid data, always focusing on your customers’ wishes and requirements.
You master the different Six Sigma methods in the toolbox necessary to develop robust services, products, and processes that can meet Six Sigma quality levels.
Who is it aimed at?
This DFSS Black Belt training is for you who wish to be a Six Sigma expert. You will learn a structured and data-driven approach, equipping you to be a project leader on complex, often cross-disciplinary and cross-organisational, DFSS projects and development initiatives.
More companies have realised that the Six Sigma method can help increase customer satisfaction by ensuring robustness in products, processes, and services from the start, thus improving the bottom line. This means that companies using Six Sigma thinking can achieve significant quality improvements, save resources, and enhance competitiveness.
Content of DFSS Black Belt training
Duration: 19 days
The training will focus on DFSS and the tools naturally associated with the method. Here we build on your Six Sigma competencies and delve into individual points such as advanced statistics, hypothesis testing and control, and focus on change management and how you facilitate project teams.
The teaching takes place in modules, divided according to the individual steps in the IDOV model, where each step has its own tools and methods attached.
The most relevant methods and tools will be explained in combination with case studies and associated exercises, giving you the opportunity to test the theory in practice.
You will be certified at expert level and therefore have to complete two development projects for your company, receiving coaching and guidance along the way. This way, you can create results for your company already during the training.
The first project is prepared between the teaching modules, and the next one after completing the instruction.
The DMAIC model
We review Six Sigma's basic structure and give you a thorough introduction to the DMAIC model (Define, Measure, Analyse, Improve, Control), which is one of the most commonly used approaches in optimisation projects for existing processes, products, and services.
We review, among other things:
- The DMAIC model
- Process description
- Value Stream Mapping (VSM)
- Project basis
Identify
This phase is about identifying your customers' needs and converting them into technical requirements.
Here are some of the aspects we cover:
- Project basis
- Process overview
- Customer focus
- "The voice of the customer"
- Identifying customer requirements
- Kano Model
- Affinity Diagram – KJ analysis
- QFD (Quality Function Deployment)
- Implementation of Quality Function - Translate customer requirements into design requirements
- Learn what you can from the defect
- Basic statistics: e.g., Pareto, histogram, box plot, time-series plot
- Measure the positive process
Design
The design phase emphasises your Critical to Quality criteria (CTQs), where you identify functional requirements, develop potential design concepts, evaluate various alternatives and select the most suitable based on preliminary analyses, tests, and risk assessments.
We review, among other things:
- QFD (Quality Function Deployment)
- P-Diagram
- Develop Conceptual Solutions
- Design FMEA & Process FMEA (Failure Mode and Effects Analysis)
- Select the Best Concepts
- Measurement System Analysis
- Confidence Intervals (statistics)
- Hypothesis Testing
Optimise
Optimise and refine your design. In this phase, you assess tolerances, predict performance, and test alternative designs and design elements.
We go through:
- Simple Linear Regression
- Multiple Regression
- Multi-Vari Analysis (diagrams)
- Design of Experiments (DOE)
- Full Factorial DOE
- Design for Manufacturing and Assembly (DFMA)
- Determine optimal targets and tolerances for X's - Monte Carlo Simulation
- Error-proofing
- Fishbone Diagram
- 5 x Whys
Verify
Verify that the design achieves its intended function and meets customer needs.
The verification phase consists of testing and final approval of the design. Prototypes are tested for performance, error states, reliability and any potential risks before final approval.
- Complete "Design Verification Plan" (DVP)
- Complete “Design/Process FMEA”
- Design Validation
- Process Stability and Capability
- Robust Tolerance Analysis
- Assessment Test
Advanced Topics
I dette modul går vi i dybden med avancerede analyse- og statistik-tilgange.
- Stikprøvestørrelse
- Type 1 MSA (Målesystemsanalyse)
- Standard driftsprocedurer (SOP Standard Operating Procedure)
- Avanceret hypotesetestning (ikke-parametriske test), og risikovurdering.
- Robust Engineering (Design of Experiments - DOE)
- ”Is / Is not” problemløsningsanalyse
- 8D-rapport
Soft Skills
In this module, we focus on leadership, presentation and coaching techniques.
- Basic Project Management
- ADKAR Change Management
- Presentation Skills
- Coaching Skills
- "Train the Trainer"
Project, Exam & Certification
Project
To be certified as a Design for Six Sigma Black Belt, you must have completed two IDOV development projects in your own organisation. The project result must show improvement in an important performance measurement for the organisation's strategy.
The projects must be completed within 18 months from the start of your training, concluding with the submission of a project report and an oral defence of the task.
The report is a detailed dissertation containing reflections on the process and the results you have achieved (what you did, why you did it and what consequences it had). Additionally, you must be able to document the use of different Six Sigma problem-solving tools.
Coaching
You have the opportunity for ongoing sparring and guidance from Six Sigma coaches with extensive practical experience and insight in the implementation of DFSS projects. Your coach helps you ensure progress in your project. You will typically use 3-4 hours of personal coaching per IDOV phase, where you get targeted help for your specific problem (the hours cannot be accumulated, but must be used continuously). With this valuable support, it is easier for you to maintain the thread through the phases and create the best possible project yield.
Exam
Following the last teaching session, there will be a written examination (multiple choice test) where you need to achieve a minimum of 70% correct answers to pass. Afterward, completion of your practical projects, project report, and oral defence awaits before you can be fully certified.
Certification
Certification is based on your completed projects. The certification is a recognition that you have proven you can put theory into practice and create significant results. Be aware that passing is not guaranteed. However, we, of course, do not propose you for examination until we believe you are ready.
Presentation and Celebration
You will present your project report to your teacher and an external examiner. Your leader and project group are welcome to participate as certification is also a small celebration, where your and the project's results are acknowledged and celebrated. This is a milestone in your career!
The Practical
Duration: 19 days of physical instruction split into 7 modules, spread over approximately 7 months.
Time for instruction: Typically from 8.00 to 16.00
Teaching form: The training will primarily take place as physical group instruction
Class size: We have small classes with a maximum of 12 participants. You follow the same class throughout the entire course
Preparation: Expect homework between instructional modules
Outcome – What competences does it provide?
After completing the training, you will have learned what is necessary to ensure robustness in the design of new products, services and processes. Your learning will occur through both theory and practical exercises, where you practise using key Six Sigma tools.
You will possess the competences to lead development projects and local improvement initiatives, complete a full IDOV project, independently analyse process data, conduct sampling, test hypotheses and establish control plans with associated statistical process control.
- You will be capable of guiding and directing the development work with robust, data-driven decisions based on customer understanding and process insight.
- Utilise tools and methods that ensure support in the organisation for improvement initiatives.
- You will learn to use different optimisation tools for projects as well as in your daily work.
- A new perspective on the use of data-driven solutions for problem-solving.
- Define and separate external and internal customer needs, and transform these so they become operational and measurable in relation to the process output.
- Work with Cost of Poor Quality (COPQ), so there is evidence of what the poor quality costs the company.
- Understand the importance of using data and measurement system analyses to ensure data validity.
- Use Statistical Process Control (SPC) as a management method.
- Perform risk analyses (FMEA). For example, in connection with root cause analysis and risk assessment of future solutions.
- Use the IDOV method to perform structured root cause analyses, with essential tools such as statistical hypothesis tests and Design of Experiments (DOE).
- Design and produce solutions with Design of Experiments (DOE). Carry out experiments with both screening and real optimisation.
Our Other Design for Six Sigma Trainings
White
Belt
Design for Six Sigma White Belt
Get a short but thorough introduction to Design for Six Sigma and the associated tools, so you are aware of and understand how a DFSS project works.
Duration: 1 day of teaching
Yellow
Belt
Design for Six Sigma Yellow Belt
Gain insight into the fundamental principles of Design for Six Sigma, so you can become an active team member in DFSS projects, and assist Green Belts and Black Belts.
Duration: 3 days of teaching
Green
Belt
Design for Six Sigma Green Belt
Gain great practical insight and become capable of leading and implementing DFSS projects within your own field or department. Green Belts often spend about 25% of their working time on this.
Duration: 13 days of teaching + work on your own practical project
Master Black
Belt
Design for Six Sigma Master Black Belt
You will become the expert who, with great professionalism, can solve critical and complicated quality challenges, take on a strategic leadership role in the organisation, and train and coach other Green Belts and Black Belts in the method.
Duration: typically 9-11 days of teaching (final number agreed individually) + practical project and coaching of Green Belts and Black Belts
Why choose eye4improve
- Skillful and experienced instructors
- You gain skills you can use in the real world
- We alternate between theory and practical exercises, so you are involved in the teaching
- The complex material is served in an easy-to-understand way with plenty of examples and exercises
- You gain skills you can use in the real world
- You get a high academic level
- We educate practitioners
Let’s have a chat
Do you need help and guidance for specific challenges that you and your company are facing?
Don’t hesitate to contact us for a non-binding conversation. Just fill out the form, and we will contact you.
+45 22996900
(09.00 – 17.00)
