The Role of the

Lean Six Sigma

Black Belt

© 2003 Alcan Inc.

Lean Six Sigma
Black Belt Improvement Process Road Map
Activities
• Review Project Charter
• Validate Problem Statement
and Goals
• Validate Voice of the Customer
& Voice of the Business
• Validate Financial Benefits
• Validate High-Level Value
Stream Map and Scope
• Create Communication Plan
• Select and Launch Team
• Develop Project Schedule
• Complete Define Gate
Tools
• Project Charter
• Voice of the Customer and
Kano Analysis
• SIPOC Map
• Project Valuation / EVA
Analysis Tools
• RACI and Quad Charts
• Stakeholder Analysis
• Communication Plan
• Effective Meeting Tools
• Inquiry and Advocacy Skills
• Time Lines, Milestones,
and Gantt Charting
• Pareto Analysis
Belbin Analysis
•The Role of the LSS
• Value Stream Map for Deeper
Understanding and Focus
• Identify Key Input, Process and
Output Metrics
• Develop Operational Definitions
• Develop Data Collection Plan
• Validate Measurement System
• Collect Baseline Data
• Determine Process Capability
• Complete Measure Gate
Identify and Implement Quick Improvements with Kaizen
• Value Stream Mapping
• Value of Speed (Process Cycle
Efficiency / Little’s Law)
• Operational Definitions
• Data Collection Plan
• Statistical Sampling
• Measurement System Analysis
(MSA)
• Gage R&R
• Kappa Studies
• Control Charts
• Histograms
• Normality Test
• Process Capability Analysis
Black Belt
• Identify Potential Root
Causes
• Reduce List of Potential
Root Causes
• Confirm Root Cause to
Output Relationship
• Estimate Impact of Root
Causes on Key Outputs
• Prioritize Root Causes
• Complete Analyze Gate
• Process Constraint ID and Takt
Time Analysis
• Cause & Effect Analysis
• FMEA
• Hypothesis Tests/Conf. Intervals
• Simple & Multiple Regression
• ANOVA
• Components of Variation
• Conquering Product and
Process Complexity
• Queuing Theory
© 2003 Alcan - George Group Curriculum
• Develop Potential Solutions
• Evaluate, Select, and Optimize
Best Solutions
• Develop ‘To-Be’ Value Stream
Map(s)
• Develop and Implement Pilot
Solution
• Confirm Attainment of Project
Goals
• Develop Full Scale
Implementation Plan
• Complete Improve Gate
Kaizen, 5S, NVA Analysis,
Generic Pull Systems,
Four Step Rapid Setup Method
• Replenishment Pull/Kanban
• Stocking Strategy
• Process Flow Improvement
• Process Balancing
• Analytical Batch Sizing
• Maintenance Excellence
• Design of Experiments (DOE)
• Solution Selection Matrix
• Piloting and Simulation
• Implement Mistake Proofing
• Develop SOP’s, Training Plan
& Process Controls
• Implement Solution and
Ongoing Process
Measurements
• Identify Project Replication
Opportunities
• Complete Control Gate
• Transition Project to Process
Owner
• Mistake-Proofing/
Zero Defects
• Standard Operating
Procedures (SOP’s)
• Process Control Plans
• Visual Process Control Tools
• Statistical Process Controls
(SPC)
• Solution Replication
• Project Transition Model
• Team Feedback Session
Slide 2
 Learning Objectives
 Understand how the Black Belt position enhances the
value of the organization

The Role of the LSS Black Belt © 2003 Alcan - George Group Curriculum Slide 3
 The Black Belt Mission
 We need to become secure in our abilities to collect,
analyze, and employ data.

 We need to help our organizations successfully collect

important data and convert it into usable information.

 It is by using data that we increase the effectiveness of

our decisions, communications, and alignment of our
limited resources.

The Role of the LSS Black Belt © 2003 Alcan - George Group Curriculum Slide 4
 Black Belt Roles:
What Do You Think?
 The roles of the Lean Six Sigma Black Belt
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

The Role of the LSS Black Belt © 2003 Alcan - George Group Curriculum Slide 5
 What Are the Roles of a
Lean Six Sigma Black Belt?
Black Belts:
 Are contributors from various disciplines
 Are Change Agents for the company
 Should stimulate management thinking by posing new ways of
doing things
 Challenge conventional wisdom by demonstrating the successful
application of new methodologies
 Carry a very high level of peer respect and are clearly seen as
leaders
 Manage risks, help set direction, and lead the way to
breakthrough improvement

The Role of the LSS Black Belt © 2003 Alcan - George Group Curriculum Slide 6
 Qualities of a Successful
Black Belt
 Process/product knowledge

 Basic statistical knowledge

 Understands the organization

 Good communication skills

 Self starter/motivated

 Open-minded

 Eager to learn new ideas

 Desire to drive change

 Team player

 Respected by others

 Track record of results

The Role of the LSS Black Belt © 2003 Alcan - George Group Curriculum Slide 7
 Black Belt Roles
 Leads strategic, high impact process improvement projects

 Masters basic and advanced breakthrough tools and

statistics

 Deploys techniques of define, measurement, analysis,

improvement and control

 Learns through intensive training program

Black Belts are Change Agents

for institutionalizing Lean Six Sigma

The Role of the LSS Black Belt © 2003 Alcan - George Group Curriculum Slide 8
 Black Belt Deliverables

R = Q x A

Quality of
Results of the Acceptance of
Project = the
Solution
x the Organization

The Role of the LSS Black Belt © 2003 Alcan - George Group Curriculum Slide 9
 Black Belts Have a Heavy Load
 Understanding/applying the Lean Six Sigma training on
projects

 Leading and influencing team members that the Lean Six

Sigma methodology is the right thing to do

 Ensuring that process improvements stay in place over time

 Providing face-to-face feedback to the management on the

project status

 Tracking and reporting project results to management

 Changing the culture

The Role of the LSS Black Belt © 2003 Alcan - George Group Curriculum Slide 10
 What Black Belts Have
Going for Them
 You are going to work on one of managements’ highest
priorities.

 You will have upper management support and commitment.

 Your value will be measured by the savings of your highly

visible project.

 You will build the teams to help the business grow with a
high level of empowerment.

 Data and facts will be your guide.

 That satisfaction that comes with a job well done.

The Role of the LSS Black Belt © 2003 Alcan - George Group Curriculum Slide 11
 The Question Is…
 Why wouldn’t you want to be a Black Belt?

 This skill of solving problems with data will stay with you
throughout your career.

The Role of the LSS Black Belt © 2003 Alcan - George Group Curriculum Slide 12
 Takeaways
 The roles the Black Belt is expected to fill

 The qualities of a successful Black Belt

 The Black Belt deliverables

The Role of the LSS Black Belt © 2003 Alcan - George Group Curriculum Slide 13