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ACADEMY OF BUSINESS IMPROVEMENT LEADERSHIP

AOBIL

www.aobil.com.au (Australia)

LEAN SIX SIGMA CERTIFICATION OVERVIEW

Lean Six Sigma Qualifications for Green Belts and Black Belts

Certified Business Improvement Leaders

_____________________________________________________________________________________________

VERSION 2015.02

Accredited Lean Six Sigma / Business Improvement Leadership Qualifica<ons

COPYRIGHT © Soarent Vision Pty. Ltd.: all rights reserved.

This document may be copied electronically in whole, but not in part, onto one or more computers within the authorised recipient’s organisa@on for internal use and to distribute access for authorised employees only.

At no @me may this document, in any form, be placed on the internet or on any other publicly accessible medium. No other use of this document may be made by any third party. No other reproduc@on rights are granted. No right to make deriva@ve works are granted.

AOBILProfessional Development -‐ Any Where -‐ Any Time -‐ Any Course

HEAD OFFICE (CURRUMBIN WATERS, AUSTRALIA) Postal: PO Box 1027 Mount Ommaney, Qld AUSTRALIA 4074 Phone (Australia only) 1300 551 294 Phone +61 (0)438 128 338 Email [email protected] Web www.aobil.com.au

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CONTENTS

1. Issuing Qualifications 3 1.1 Qualifications 3 1.2 Terms and Conditions 3 1.3 Body of Knowledge 3

Soarent Publications (available from AOBIL.com.au) 3

2. Certification Instructions for Green Belt and Black Belt Candidates 4 2.1 Overview of the Standard Process for Members training with AOBIL 4 2.2 Recognition of Prior Learning 5 2.3 What You Need To Do Now 5

3. Are You Ready For Certification? 6 3.1 Checklist for Members who train with AOBIL 6 3.2 Documents Required 6

4. Preparing for the Certification Examinations 9 4.1 Body of Knowledge 9 4.2 Study Guide 9



1. Issuing Qualifications1.1 Qualifications Successful applicants may be issued the following qualifica@ons:

• Statement of Qualifica@on as a Lean Six Sigma Green Belt

• Statement of Qualifica@on as a Lean Six Sigma Black Belt

• Statement of Qualifica@on as a Lean Six Sigma Master Black Belt

NOTE: LSS Master Black Belt details are not covered in this document.

1.2 Terms and Conditions The terms and condi@ons under which AOBIL issues these qualifica@ons meet standards as determined by the governing body of ter@ary qualifica@ons in Australia -‐ the Australian Skills Quality Authority. ( www.asqa.gov.au ) and the Ins@tute of Business Improvement Leadership (IBIL).

1.3 Body of Knowledge Text Books All examina@ons are based on the body of knowledge contained in these materials.

• ‘Process Alchemy -‐ 2nd Edi@on’, Soarent, Brisbane (2007)

• ‘Process Mastery with Lean Six Sigma -‐ 2nd Edi@on’, Soarent, Brisbane (2009)

• ‘Its S@ll Not a Problem’, Soarent, Brisbane (2005) OR Systema@c Problem Solving for Managers (2013) Relevant Standards

• Various AS/NZ Standards (e.g.; Sampling, Risk Management)

Soarent Publications (available from AOBIL.com.au)Systema<c Problem Solving

for Managers

A systema@c approach to problem solving in business available in electronic format from Amazon and iTunes.

Process Alchemy 2nd Edi<on

A hard copy guide to the leadership of business

improvement using modern Lean and Six Sigma methodologies.

It’s STILL Not a Problem

A systema@c approach to problem solving in business which complements the Lean and Six Sigma toolkits with

specific tools for trea@ng event based problems.

Process Mastery with Lean Six Sigma

Our best selling book by far, the second edi@on of this prac@cal guide to the

u@lisa@on of Lean and Six Sigma is one of the most

popular Black Belt handbooks in the world today.

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2. Certification Instructions for Green Belt and Black Belt Candidates2.1 Overview of the Standard Process for Members training with AOBIL

➀ TRAINING Candidates enrol and undertake formal Lean Six Sigma training with AOBIL

Green Belts = 4 Modules (classroom or online)

Black Belts = 2 Modules (online)

➁ PROJECTS Candidates apply the methodology in a work based environment.

OPTION 1 -‐ Par@cipants lead at least 1 work based business improvement project that adds quan@fiable value to a company using relevant Lean and Six Sigma methodologies

OPTION 2 -‐ Candidates ajend a 3-‐day Masterclass where they u@lise the AOBIL simula@on to complete a Lean Project and a Six Sigma Project with other candidates.

It is important to recognise that while a minimum of one project must be completed for Green Belt, in some cases two or more projects will be required to demonstrate competency for the more comprehensive levels. This is par@cularly important as Lean and Six Sigma address different outcomes.

Black Belt Candidates must lead a total of at least 3 work based business improvement projects that add quan@fiable value to a company

➂ APPLICATION Candidates obtain a cer<fica<on kit

(the kit is provided when you purchase the LSSGB or LSSBB Cer@fica@on)

Candidates apply for cer<fica<on and lodge evidence of competency for assessment

Note: Candidates who follow the Masterclass route u@lise work from that class.

➃ REVIEW Applica@ons are reviewed and candidates no<fied of progress status

➄ EXAMINATION FOR GREEN BELTS

Formal examina<on is undertaken using the AOBIL online planorm

Notes: Candidates who follow the Masterclass route undertake GB exam during that class.

Black Belt candidates who complete QDM and QFD modules do not need to sit an exam.

➅ FOLLOW UP Where gaps exist, ac@on is taken to close those gaps which might include formal training (if not previously undertaken) and prac@cal demonstra<on of competency

➆ CERTIFICATION Formal cer<fica<on is issued for the full qualifica<on as determined by the level of competency demonstrated

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2.2 Recognition of Prior Learning Yes, AOBIL will recognise training undertaken with other organisa@ons. The RPL process differs slightly from the standard cer@fica@on process in two ways:

• Candidates have par@cipated in some formal training with another organisa<on; and

• Candidates must assemble a comprehensive submission that demonstrates their competency for all elements of the qualifica@on being sought. The onus remains with the par@cipant to demonstrate competency.

Note: Details of the RPL process are provided in a separate document upon request.

2.3 What You Need To Do Now

➀ DOCUMENTS Choose the relevant Online Cer<fica<on Product (available on the AOBIL web site)

Once you have acquired it, you will receive an LSS Cer<fica<on Pack as well as access to the examina@on planorm on the specified dates

Follow the AOBIL LSS Cer<fica<on Instruc<ons provided in the pack

➁ EVIDENCE Collate evidence and assemble it in a form that can be reviewed by the assessor

• Electronic form with all evidence assembled in the way described in the instruc@ons provided

• Details are provided in the AOBIL Cer<fica<on Instruc<ons provided

➂ ASSESSMENT Lodge your Applica<on for Assessment and evidence of competency with the Learning Coordinator using the lodgement method described in the instruc@ons provided

➃ EXAMINATION Undertake the Examina@on on the dates specified using the AOBIL planorm



3. Are You Ready For Certification?3.1 Checklist for Members who train with AOBIL

3.2 Documents Required

Notes:

• Comple@on of the Lean Six Sigma Green Belt is a pre-‐requisite to the issue of a Lean Six Sigma Black Belt qualifica@on.

• This list is not your assignment list, only a self assessment aid to the documents that will be required -‐ a checklist is provided in your Cer@fica@on Kit to help you finalise your documented evidence of competency.

• Candidates who par@cipate in AOBIL’s 3-‐day Cer<fica<on Masterclass will have access to all of the Green Belt level documents at the end of the class

LSS Green Belt LSS Black Belt

#1

Facilitated the comple@on of at least 1 workplace improvement project using Lean / Six Sigma

methodology in a DMAIC process

OR

Completed AOBIL’s 3-‐day Cer@fica@on Masterclass

☐#1

Have been Cer@fied by AOBIL as a Lean Six Sigma Green Belt

☐

#2

Can provide an Affidavit signed by the Line Manager / Project Champion to the effect that the project has produced a quan@fiable benefit to the

host organisa@on

OR

Completed AOBIL’s 3-‐day Cer@fica@on Masterclass

☐

#2

Facilitated the comple@on of at least 3 improvement projects that demonstrate competency with both Lean and Six Sigma methodologies using a DMAIC process

☐

#3

Have documented evidence of competency relevant to the level of qualifica@on I am seeking

(The list below give you an indica@on of the types of documents required for the full qualifica@on)

☐

#3

Can provide Affidavits signed by respec@ve Line Managers / Project Champions to the effect that the projects have produced quan@fiable benefit to

the host organisa@on

☐

#4

Have documented evidence of competency relevant to the level of qualifica@on I am seeking

(The list below give you an indica@on of the types of documents required for the full qualifica@on)

☐



GENERIC PROJECT EVIDENCE (APPLIES TO BOTH LEAN AND SIX SIGMA PROJECTS)

LEAN SPECIFIC PROJECT WORK DOCUMENTS

GREEN BELT

Project Charter (incl. problem statement / defini@on, scoping, business case etc) ☐

Stakeholder Management Details (descrip@on of how key people were managed) ☐

Project Plan (showing a plan for the comple@on of the improvement project) ☐

Project Tracking (whatever mechanism used to track project progress and business efficiency and cost improvements)

☐

Mee<ng Agendas (using the OPRA format presented in Process Mastery with Lean Six Sigma 2nd Edi@on) ☐

Implementa<on Plan for Solu<ons (how you planned the roll out of solu@ons) ☐

Project Risk Management Plan (must include planned controls for managing iden@fied implementa@on project risks)

☐

Final Project Report (showing applica@on of Lean Six Sigma and DMAIC methodology) ☐

Documenta<on of Lessons Learned (how you reported and shared learnings) ☐

Affidavit of Project Comple<on (signed affidavit that supports claims that you led a project that returned a quan@fiable benefit to the organisa@on)

☐

GREEN BELT

Value Stream Analysis / Map (shows key metrics through the value stream and includes metrics around cost ($) and value of @me -‐ if no cost metrics, some form of cost analysis must be provided separately)

☐

Time Value Analysis (includes iden@fying VA and NVA @me and the cost of that NVA @me) ☐

Process Balancing (incl. Take Time Chart iden@fying constraints and methods used for achieving balance across a process)

☐

Lean Tool Applica<on for Waste Iden<fica<on 1 (cross func@onal flowcharts, spagheu diagrams etc) ☐

Lean Tool Applica<on for Waste Iden<fica<on 2 (takt @me charts) ☐

Lean Tool Applica<on for Waste Removal 1 (process balancing, work cell design etc) ☐

Lean Tool Applica<on for Waste Removal 2 (a pull system) ☐

Quick Changeover Improvement (incl. SMED report with evidence of improvement) ☐

5S Evalua<on and Evidence of Improvement (incl. audit report and before and aver photos) ☐



SIX SIGMA SPECIFIC PROJECT WORK DOCUMENTS

Notes:

** Black Belt Candidates who successfully complete the assignments from the 2 Black Belt training modules (QDM and QFD) will have met these document requirements.

GREEN BELT BLACK BELT

Data Collec<on Plan (a plan for the collec@on of key Y and X data, incl. categorical and numerical Xs, opera@onal defini@ons, sampling plan etc)

☐Gage R&R (sta@s@cal output and applica@on of gage repeatability and reproducibility tests, evidence of analysis of excess varia@on) **

☐

Baseline Process Capability (process capability methods which might include Cp & Cpk or Sigma Quality and yield calcula@ons)

☐Correla<on and Linear Regression Study Output (correla@on results, XY plots, linear regression study AND interpreta@on) **

☐

Stability Analysis Control Charts (controls charts with interpreta@on and findings)

☐Hypothesis Tes<ng Reports with Conclusions (parametric and / or non parametric tests, anova etc) **

☐

Charts and Data Presenta<on (include charts used for studying cause and effect rela@onships with interpreta@on and findings)

☐ Designed Experiment (include design PLUS first run results PLUS final model and interpreta@on) **

☐

Root Cause Analysis Tools (evidence of use of ishikawa, 5 whys, cause effect structure trees etc)

☐

Process FMEA (evidence of analysis PLUS implementa@on of ac@ons to improvement PLUS new process flow chart)

☐First Level House of Quality -‐ QFD (first level hours PLUS descrip@on of the course of ac@on this led to) **

☐



4. Preparing for the Certification ExaminationsNOTE: This sec@on is relevant to:

(a) Soarent Vision classroom course students trained before 2014 who have not undertaken Cer@fica@on Examina@ons (GB and BB); and

(b) AOBIL Members and Students who have not yet completed the final Cer@fica@on Examina@on for the Green Belt level.

4.1 Body of Knowledge All topics can be studied in the primary training text book:

• 2nd Edi@on of Process Mastery with Lean Six Sigma

This is complemented by the body of work presented in the other textbooks shown below.

4.2 Study Guide

4.2.1 Green Belt Certification Examination Part A and B - Lean Focus Relevant to:

• Soarent Vision trained students (pre-‐2014)

• AOBIL trained Green Belt level Candidates

Printed Book -‐ It’s STILL Not a Problem

Printed Book -‐ Process Mastery with Lean Six Sigma

Printed Book -‐ Process Alchemy 2nd Edi<on

Digital Book -‐ Systema<c Problem Solving for Managers

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Topic Topic

Business / Process Waste Various approaches to process improvement

Lean project characteris@cs Project repor@ng structures and progress reviews

Stakeholder reviews Opera@ng agreements

Process flowchar@ng Value added @me / non value added @me

Finding sources of waste Process cycle efficiency (PCE) metrics

Generic pull systems Quick changeover improvements / SMED

Process balancing Value stream analysis



4.2.2 Green Belt Certification Examination Part C and D - Six Sigma Focus Relevant to:

• Soarent Vision trained students (pre-‐2014)

• AOBIL trained Green Belt level Candidates

4.2.3 Black Belt Certification Examination Part E and F - Advanced Statistics and Lean Metric Focus Notes:

1. Parts A to D inclusive must be completed by candidates who have not completed the Green Belt examina@on.

2. Exam par@cipa@on is not required of AOBIL Members who complete the 2x LSSBB training modules.

Relevant to -‐ Soarent Vision trained Black Belt level Candidates (pre 2014)

Topic Topic

Six Sigma versus Lean 7 Wastes

Facilita@ve leadership Team development

Facilita@ng crea@vity, innova@on and idea genera@on Six sigma project characteris@cs

Project repor@ng structures and progress reviews Stakeholder reviews

Project chartering Project tollgates and post implementa@on review

Es@ma@ng financial benefits Sample size calcula@ons and sampling methods

Data collec@on and analysis Graphical data representa@on

Process capability (including process sigma quality, yield, Cp and Cpk etc) Frequency distribu@ons and their graphical display

Control charts Descrip@ve sta@s@cs

Performance monitoring Performance control

Correla@on and linear regression FMEA

Topic Topic

Descrip@ve sta@s@cs Central limit theorem

Hypothesis tes@ng (parametric and non parametric) Design of experiments (full and frac@onal factorial DOE)

Two Way ANOVA Process Capability

Confidence Intervals Measurement System Analysis (Gage R&R)

Pearsons Correla@on Linear Regression

Visual Display of Rela@onships Run Charts

LTF Calcula@ons PCE Calcula@ons



AOBILProfessional Development - Any Where - Any Time - Any Course

HEAD OFFICE (CURRUMBIN WATERS, AUSTRALIA)Queensland, AUSTRALIA

P 1300 551 294 (Australia)

P +61 (0)438 128 338

E [email protected]

W www.AOBIL.com.au


http://www.AOBIL.com.au