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National GuardBlack Belt Training

Module 02

Course Schedule(Table of Contents)

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NG BB Course NavigationBy Phase

This course integrates the CPI DMAIC and 8-Step Methodologies using Lean and Six Sigma tools

The course modules, tollgate templates and tollgate approvals are arranged by project phases

By Week

A comprehensive Table of Contents is provided for all CPI modules taught in this course in chronological order

Course Agendas are broken out by week, as follows:

Week One – Define and Intro to Measure, Simulation Round 1

Week Two – Measure and Intro to Analyze, Simulation Round 2

Week Three – Analyze and Intro to Improve, Simulation Round 3

Week Four – Improve and Finish Control, Simulation Round 4

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CPI Process Road Map – By Phase

• Identify Problem

• Validate Problem

• Establish Strategic

Alignment

• Gather Voice of the

Customer & Business

• Create Goal Statement

• Validate Business Case

• Determine Scope

• Select Team

• Develop Timeline

• Communicate Plan

• High-Level Process Map

• Complete Define Gate

• Implement Mistake Proofing

• Develop SOPs, Training Plan

and Process Controls

• Implement Solution

• Establish Ongoing Process

Measurements

• Identify Project Replication

Opportunities

• Estimate Final Financial /

Operational Benefits

• Transition Project to Process

Owner

• Develop Audit / Response

Plan

• Create Final Storyboard

• Complete Control Gate

• Identify Potential Root

Causes (Fishbone, 5

Whys, etc)

• Reduce List of Potential

Root Causes (Affinity,

Pareto, etc)

• Confirm Root Cause to

Output Relationship

• Estimate Impact of Root

Causes on Key Outputs

(Hypothesis Tests,

Regression, etc)

• Prioritize Root Causes

(XY Matrix, etc)

• Complete Analyze Gate

• Map Current Process

• Go & See Process

• Identify Bottlenecks

• Create Value Stream Map

• Identify Key Input, Process

and Output Metrics

• Develop Operational

Definitions

• Develop Data Collection

Plan

• Validate Measurement

System

• Collect Baseline Data

• Identify Performance Gaps

• Complete SWOT Analysis

• Estimate Financial /

Operational Benefits

• Determine Process Stability

• Determine Process

Capability

• Complete Measure Gate

• Develop Potential Solutions

• Develop Evaluation Criteria

• Select Best Solutions

• Apply Lean Concepts

• Develop Future State

Process Map(s)

• Develop Pilot Plan

• Pilot Solution

• Develop Full Scale Action /

Implementation Plan

• Complete Improve Gate

1.Validate the

Problem

4. Determine Root

Cause

3. Set Improvement

Targets

5. Develop Counter-

Measures

6. See Counter-MeasuresThrough

2. IdentifyPerformance

Gaps

7. Confirm Results

& Process

8. StandardizeSuccessfulProcesses

Define Measure Analyze ControlImprove

8-STEP PROCESS

Integrated CPI Methods & Tools

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Table of Contents: Define

Module Number Module Title

NG BB 01 Introduction

NG BB 02 Table of Contents

NG BB 03 CPI Methodology

NG BB 04 DEFINE Roadmap

NG BB 05 Roles and Responsibilities

NG BB 06 Project Charter

NG BB 07 Multi-Generation Project Planning

NG BB 08 Change Management

NG BB 09 Project Management

NG BB 10 Financial Benefits

NG BB 11 Power Steering

NG BB 12 High-Level Process Map

NG BB 13 Voice of Customer

NG BB 14 DEFINE Tollgate

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Table of Contents: Measure

Module Number Module Title

NG BB 15 MEASURE Roadmap

NG BB 16 Principles of Lean

NG BB 17 Take Time

NG BB 18 Theory of Constraints

NG BB 19 Document and Analyze the Process

NG BB 20 Data Collection

NG BB 21 Intro to Minitab

NG BB 22 Process Measurement

NG BB 23 Measurement System Analysis - Introduction

NG BB 24 Measurement System Analysis - Continuous

NG BB 25 Measurement System Analysis - Attribute

NG BB 26 Control Charts

NG BB 27 Process Capability

NG BB 28 MEASURE Tollgate

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Table of Contents: Analyze

Module Number Module Title

NG BB 29 ANALYZE Roadmap

NG BB 30 Basic Tools

NG BB 31 Cause and Effect (XY) Matrix

NG BB 32 Failure Modes and Effects Analysis

NG BB 33 Hypothesis Testing Basics

NG BB 34 Analysis of Variance (ANOVA)

NG BB 35 Hypothesis Test - Attribute Data

NG BB 36 Simple Linear Regression

NG BB 37 Multiple Regression

NG BB 38 ANALYZE Tollgate

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Table of Contents: Improve

Module Number Module Title

NG BB 39 IMPROVE Roadmap

NG BB 40 Solution Selection

NG BB 41 6S

NG BB 42 Visual Management

NG BB 43 Standardized Work

NG BB 44 Process Balancing

NG BB 45 Quick Change Over

NG BB 46 Mistake Proofing

NG BB 47 Basic Design of Experiments

NG BB 48 Pilot the Solution

NG BB 49 Risk Assessment

NG BB 50 Rapid Improvement Event

NG BB 51 IMPROVE Tollgate

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Table of Contents: Control

FINAL BB EXAM

Module Number Module Title

NG BB 52 CONTROL Roadmap

NG BB 53 Process Control

NG BB 54 Sustain the Gain

NG BB 55 CONTROL / FINAL Tollgate

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Week One Agenda

Start End Monday Tuesday Wednesday Thursday Friday

8:00 8:30 Teachbacks Teachbacks Teachbacks Group Activity

8:30 9:00 07 MGPP 15 Measure RM Phase Markers

9:00 9:30

9:30 10:00

10:00 10:30

10:30 11:00

11:00 11:30

11:30 12:00

12:00 12:30

12:30 13:00 02 Course Schedule Next Steps

13:00 13:30

13:30 14:00 Video

14:00 14:30 04 Define Roadmap

14:30 15:00

15:00 15:30

15:30 16:00

16:00 16:30

16:30 17:00

Week 1 Exam

NG Black Belt Week 1

10 Finincial

Benefits

17 Takt Time

18 Theory of

Constraints

Welcome Address

Lunch Break

01 Introduction

19 Document &

Analyze the

Process06 Project Charter

03 CPI Methodology

05 R&R

14 Define Tollgate11 Power Steering

09 Project Mgt 12 SIPOC

13 VOC

08 Change Mgt DMAIC Simulation

Round One 16 Principles of

Lean

VSM Exercise

20 Data Collection09 Project Mgt

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Week Two Agenda

Start End Monday Tuesday Wednesday Thursday Friday

8:00 8:30 Teachbacks Teachbacks Teachbacks Teachbacks Group Activity

8:30 9:00 Phase Markers

9:00 9:30

9:30 10:00

10:00 10:30

10:30 11:00

11:00 11:30

11:30 12:00

12:00 12:30

12:30 13:00 Project Briefs Project Briefs Project Briefs Project Briefs Next Steps

13:00 13:30

13:30 14:00

14:00 14:30 29 ANALYZE RM

14:30 15:00

15:00 15:30

15:30 16:00

16:00 16:30

16:30 17:00

28 MEASURE

Tollgate

27 Process

Capability

30 Basic Tools

DMAIC Simulation

Round 2

31 XY Matrix

32 FMEA

Week 2 ExamDebrief Simulation21 Intro to Minitab

24 MSA

Continuous

25 MSA Attribute

24 MSA

Continuous

23 MSA Intro

26 Control Charts

NG Black Belt Week 2

21 Intro to Minitab

MSA Exercise

22 Process

Measurement

Week 2 Welcome &

Review

Lunch Break

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Week Three Agenda

Start End Monday Tuesday Wednesday Thursday Friday

8:00 8:30 Teachbacks Teachbacks Teachbacks Teachbacks Group Activity

8:30 9:00 39 IMPROVE RM Phase Markers

9:00 9:30

9:30 10:00

10:00 10:30

10:30 11:00

11:00 11:30

11:30 12:00

12:00 12:30

12:30 13:00 Project Briefs Project Briefs Project Briefs Project Briefs Next Steps

13:00 13:30

13:30 14:00

14:00 14:30

14:30 15:00

15:00 15:30

15:30 16:00

16:00 16:30

16:30 17:00

44 Process

Balancing

45 Quick Change

Over

46 Mistake

Proofing

NG Black Belt Week 3

36 Simple Linear

Regression

37 Multiple

Regression

35 Hypothesis

Testing - Attribute

Date

34 ANOVA

33 Hypothesis

Testing Basics

40 Solution

Generation

38 ANALYZE

Tollgate

Week 3 Welcome &

Review

34 ANOVA

Western Union

Video

Lunch Break

DMAIC Simulation

Pilot

DMAIC Simulation

Round 3

Week 3 Exam

41 6S

42 Visual

Management

43 Standard Work

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Week Four Agenda

Start End Monday Tuesday Wednesday Thursday Friday

8:00 8:30 Teachbacks Teachbacks Teachbacks Teachbacks Group Activity

8:30 9:00 Phase Markers

9:00 9:30

9:30 10:00

10:00 10:30

10:30 11:00

11:00 11:30 52 CONTROL RM Course Wrap Up

11:30 12:00

12:00 12:30

12:30 13:00 Project Briefs Project Briefs Project Briefs Project Briefs

13:00 13:30

13:30 14:00

14:00 14:30

14:30 15:00

15:00 15:30

15:30 16:00

16:00 16:30

16:30 17:00

55 CONTROL /

FINAL Tollgate

Final BB Exam

48 Pilot the

Solution

49 Risk

Assessment

51 IMPROVE

Tollgate

Simulation DeBrief

NG Black Belt Week 4

54 Sustain the

Gain

53 Process Control

Control Chart

Exercise

50 Rapid

Improvement

Event

DMAIC Simulation

Round 4

Lunch Break

47 DOE

Week 4 Welcome &

Review

DOE Simulation

DOE Simulation

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