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Lean Six Sigma Black Belt Syllabus

Define Phase

Covers project selection and chartering, Voice of the Customer (VOC), process mapping, stakeholder analysis, team dynamics, and Lean fundamentals.

16%
Weight
24
Questions
24
Marks

Project Selection and Chartering

  • Project charter components (problem statement, goal statement, scope, team, timeline)
  • Business case development
  • Project selection criteria (impact, feasibility, alignment)
  • SMART goals

Voice of the Customer (VOC)

  • VOC data collection methods (surveys, interviews, focus groups)
  • Kano model (basic, performance, delight needs)
  • Critical to Quality (CTQ) trees
  • CTQ flow-down from VOC
  • Affinity diagrams

Process Mapping

  • SIPOC diagram (Suppliers, Inputs, Process, Outputs, Customers)
  • Value stream mapping (VSM)
  • Process flow diagrams
  • Identifying value-added vs non-value-added steps

Lean Fundamentals

  • Eight types of waste (DOWNTIME)
  • 5S methodology (Sort, Set in Order, Shine, Standardize, Sustain)
  • Kaizen and continuous improvement
  • Value stream and flow optimization
  • Takt time calculation
  • Pull systems and Kanban

Team and Stakeholder Management

  • Stakeholder analysis and engagement
  • RACI matrix
  • Team development stages (Tuckman: forming, storming, norming, performing)
  • Conflict resolution tools
  • Communication planning

Measure Phase

Covers data collection, measurement system analysis (MSA), process capability, baseline performance, and process behavior analysis.

25%
Weight
38
Questions
38
Marks

Data Collection and Types

  • Continuous vs discrete data
  • Operational definitions
  • Sampling strategies (random, stratified, systematic)
  • Data collection plan
  • Measurement scales (nominal, ordinal, interval, ratio)

Measurement System Analysis (MSA)

  • Gauge R&R studies (repeatability and reproducibility)
  • Attribute Agreement Analysis
  • Bias, linearity, and stability studies
  • Acceptable R&R thresholds (<10%, 10–30%, >30%)
  • Gage discrimination

Process Capability Analysis

  • Cp and Cpk indices
  • Pp and Ppk indices
  • Sigma level calculation (DPMO)
  • Short-term vs long-term process capability
  • 1.5 sigma shift
  • Non-normal process capability

Probability and Statistics Foundations

  • Normal distribution properties (68-95-99.7 rule)
  • Central Limit Theorem
  • Binomial and Poisson distributions
  • Confidence intervals
  • Z-scores and area under the curve

Analyze Phase

Covers root cause analysis techniques, hypothesis testing, correlation and regression analysis, and statistical significance testing.

24%
Weight
36
Questions
36
Marks

Root Cause Analysis Tools

  • Ishikawa (fishbone) diagram
  • 5 Whys
  • Fault tree analysis
  • Failure Mode and Effects Analysis (FMEA)
  • Affinity diagrams for root cause grouping
  • Pareto analysis (80/20 rule)

Hypothesis Testing

  • Null and alternative hypotheses (H0 and Ha)
  • Type I (alpha) and Type II (beta) errors
  • P-value interpretation
  • One-tail vs two-tail tests
  • One-sample and two-sample t-tests
  • ANOVA (one-way and two-way)
  • F-test for variance equality
  • Paired t-test

Non-Parametric Tests

  • Chi-square test of independence
  • Mann-Whitney U test
  • Kruskal-Wallis test
  • Mood's Median test
  • When to use non-parametric tests

Correlation and Regression

  • Pearson correlation coefficient (r)
  • Simple linear regression
  • Multiple regression
  • R-squared interpretation
  • Regression residuals and assumptions
  • Multi-collinearity detection

Improve Phase

Covers solution generation, Design of Experiments (DOE), piloting, risk mitigation, and implementing process improvements.

21%
Weight
32
Questions
32
Marks

Solution Generation and Selection

  • Brainstorming and creative tools
  • Pugh matrix (criteria-based selection)
  • Cost-benefit analysis
  • Pilot planning and scale-up
  • Implementation planning

Design of Experiments (DOE)

  • Full factorial designs
  • Fractional factorial designs
  • Screening designs (Plackett-Burman)
  • Main effects and interaction effects
  • Response Surface Methodology (RSM)
  • Taguchi methods and robust design
  • ANOVA for DOE results
  • Confounding and aliasing

Risk and Error Proofing

  • Updated FMEA post-analysis
  • Poka-Yoke (mistake proofing) principles
  • Risk mitigation planning
  • Change management for improvements
  • Transition plan development

Control Phase

Covers Statistical Process Control (SPC), control plans, control charts, process documentation, and sustaining improvements over time.

14%
Weight
21
Questions
21
Marks

Control Charts

  • Variables charts: X-bar & R, X-bar & S, I-MR (individuals and moving range)
  • Attributes charts: p-chart, np-chart, c-chart, u-chart
  • Control chart selection criteria
  • Control limits vs specification limits
  • Special cause vs common cause variation
  • Nelson rules / Western Electric rules for out-of-control detection

Statistical Process Control (SPC)

  • SPC philosophy and implementation
  • Process stability analysis
  • Reaction plans for out-of-control signals
  • Subgroup sizing and sampling frequency

Control Plans and Documentation

  • Control plan development and components
  • Standard operating procedures (SOPs)
  • Work instruction development
  • Visual management tools
  • Process documentation and knowledge capture

Sustaining Improvements

  • Ongoing monitoring strategy
  • Handoff to process owner
  • Closing the project and reporting results
  • Lessons learned and knowledge sharing
  • Benefit realization tracking

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Simulate real exam conditions with timed practice tests

  • Exam-like environment
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Practice Tests

Comprehensive question bank with detailed explanations

  • Latest exam patterns
  • Detailed solutions

Mind Maps

Visual learning tools to connect and remember concepts

  • Interactive diagrams
  • Topic relationships

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  • Topic-wise performance analysis
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  • Weak area identification

Learning Progress

Define Phase 85%
Measure Phase 92%

Practice Test Scores

95%
Latest Score
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