1. Blended Lean Six Sigma Black Belt Training – ABInBev
Normal class introduction – “Welcome to the 3 Day session of the ASQ Lean Six Sigma Black Belt Blended training.
We’re planning to cover several topics and areas during our time today.
The scope and intent is to review some of the session materials that you have already completed—or in process of completing, to ensure that you’re comfortable with the pace of learning, the materials, and progress you have made to date on your project.
Transition to next
Week One Review
©2010 ASQ. All Rights Reserved.

2. Last Time We …
Defined our project
Leaned our processes
Learned statistical techniques
Validated our measurement system
Created standard work
Conducted hypothesis tests
Practiced coaching Green Belts
Let’s do a quick review before starting the new material.

3. Define Phase
Created the project charter – the critical first step in any LSS project
Collected Voice of the Customer
High-level process map (SIPOC)

4. A complete lean system should have:
Lean Defined
A philosophy and set of methods where waste is identified continuously and eliminated passionately.
A complete lean system should have:
Techniques/Tools
Management (mindset and accountability)
Organizational Environment (skills, culture, and behaviors)
Waste is any activity (or inactivity) that consumes resources and do not add value to the customer through the product or service.

5. Key Terms
Value-adding activities transform the product in a way the customer would be willing to pay for.
Value stream is a series of activities, both those that create value and those that do not, required to deliver a product or service.
Value stream mapping is a tool used to document (map) all activities of a value stream to clearly see waste and variations.

6. 8 Wastes The Eight Wastes EXCESS INVENTORY EXTRA PROCESSING DEFECTS
EXCESS TRANSPORTATION
WAITING
EXCESS MOTION
OVERPRODUCTION
UNUSED CREATIVITY

7. 5 S
SORT involves sorting through the contents of the workplace and removing unnecessary items.
STRAIGHTEN involves putting the necessary items in their place and providing easy access.
SHINE involves cleaning everything, keeping it clean daily, and using cleaning to inspect the workplace and equipment for defects.
STANDARDIZE involves creating visual controls and guidelines for keeping the workplace organized, orderly, and clean.
SUSTAIN involves training and discipline to ensure that everyone follows the 5S standards.

8. Seven basic probability rules
Basic Statistics
Seven basic probability rules
All events have a probability between 0 and 1.
The sum of all possible probabilities of defined events is equal to 1.00.
The probability of an event not occurring is equal to the probability of the event occurring subtracted from 1.0.
If events are mutually exclusive, the sum of the probability of occurrence of these events is equal to 1.
The probability of the joint occurrence of independent events is the product of the probability of each event.
The probability of occurrence of either or both non-independent events is the sum of the probability of each independent events minus the probability of joint events.
The probability of observing two dependent events is the product of the probability of the first event and the conditional probability of the second event, given that the first has occurred.

9. Your Turn 1
Assume a sample is selected from a normally distributed population with a mean of 12 oz and a standard deviation of .01 oz.
What percent of the sample would be expected to have a value greater than 12.02?
What percent of the sample would be expected to have a value less than 11.99?
Ten percent of the sample would be expected to have X or less. What is X?
Find the answers and draw graphs of the results using Minitab.

10. Your Turn 2
Assume a fair coin is flipped 100 times.
What is the probability of exactly 50 heads?
What is the probability of greater than 60 heads?
Assume a process creates .01 defects per unit. One hundred units were sampled. What is the probability there will be:
Zero defects?
Two defects?
Find the answers with Minitab.

11. Measurement Systems Analysis (Gage R&R)
Observed
Variation
Actual Process
Variation
Measured
Variation
Long-Term
Process
Variation
Short-Term
Process
Variation
Variance
Due to
Instrument
Variance
Due to
Operators
Repeatability
Calibration
Stability
Linearity
Reproducibility
Repeatability and reproducibility are typically the primary contributors to measurement error

12. Your Turn 3
A Green Belt conducted a gage R&R on a bottling line. He had three operators measure the temperature of the product at 20 locations in the line three times each. He sent the data in Temperature Measurement.mtw. What would you recommend?

13. Error Proofing
Error proofing is a systematic approach for anticipating and detecting potential defects and preventing them from reaching the customer (internal or external)
Proactive identification and prevention
Prevent first
Do not allow defects from going further
Intentionally designed, not by chance
At the source—close to the origination
Inexpensive first
Transparent to the operator
Absolutely reliable

14. Defining Process Capability
Principle: process capability is a ratio of process variability to design tolerance.
Process width
Design width
It is measured in several ways.

15. Process Capability Terms
Cp – Short-term process capability
For a limited period of time (not including shifts and drifts)
Does not consider process centering
Also known as process entitlement
Cpk – Short-term process capability index
Does consider process centering
Pp – Long-term process capability
For an extended period of time (including shifts and drifts)
Ppk – Long-term process capability index
Here are some basic definitions for capability indices. Note the difference between the short and long term indices.
[Briefly review.]
See formulae on next page.

16. Cp = Capability Formulae Specification Width(s)
Short-Term Process Width
Cp =
Pp =
Cpk=
Ppk= =
Specification Width(s)
Long-Term Process Width =
Lesser of: or
Lesser of: or

17. Your Turn 4
A Green Belt collected data on the fill volumes in cans. The specification limits are to with a target of 12. The data is in six pack spc. What is the capability of this process?

18. Documents layout and flow process sequence Also documents:
Standard Work
Documents layout and flow process sequence
Also documents:
• Standard W.I.P.
• Quality checks
• Safety precautions
Posted in cell
Includes visual work instructions for each operation

19. Hypothesis Testing
Enables us to determine if there is a statistically significant difference between the characteristics of interest of samples of data.

20. Testing Method Selection Matrix
There are many types of hypothesis tests we will learn to use depending on the type of data available for the inputs (Xs) and outputs (Ys).
Variable Type
Attribute Y
Count Y
Continuous Y
Discrete X
1 or 2 Treatments
Proportions
3 +Treatments Chi Square
1 or 2 Treatments Poisson
3 + Treatments Chi Square
1 or 2 Treatments T tests
3 +Treatments ANOVA
Continuous X
Logistic Regression
Least Squares Regression

21. Your Turn 5
A Green Belt collected data on Gross Line Yield before and after a process change. Did the change make a statistically significant improvement (more is better) on Gross Line Yield? The data is in Gross Line Yield.mtw.

22. Let’s get started! What’s Next?
Completing our set of hypothesis testing tools
More lean tools
Designed experiments
Control plans
Design for Six Sigma
Let’s get started!

23. Blended Lean Six Sigma Black Belt Training – ABInBev
Normal class introduction – “Welcome to the 3 Day session of the ASQ Lean Six Sigma Black Belt Blended training.
We’re planning to cover several topics and areas during our time today.
The scope and intent is to review some of the session materials that you have already completed—or in process of completing, to ensure that you’re comfortable with the pace of learning, the materials, and progress you have made to date on your project.
Transition to next
Answers to Week One Review Your Turn
©2010 ASQ. All Rights Reserved.

24. Your Turn 1 Solution 1 Calc>Probability Distributions>Normal
This will give the probability of less than 12.02, which we will subtract from 1 to get the answer.
Minitab returns
Normal with mean = 12 and standard deviation = 0.01
x P( X <= x )
So would be greater than oz.

25. Your Turn 1
Assume a sample is selected from normally distributed population with a mean of 12 oz and a standard deviation of .01 oz.
What percent of the sample would be expected to have a value greater than 12.02?
What percent of the sample would be expected to have a value less than 11.99?
Ten percent of the sample would be expected to have X or less. What is X?
Find the answers and draw graphs of the results using Minitab.

26. Your Turn 1 Solution 1 Graph
Graph>Probability Distribution Plot

27. Your Turn 1 Solution 1 Graph

28. Your Turn 1 Solution 1 Graph

29. Your Turn 1 Solution 2 Graph
Control+e to return to the last dialog box

30. Your Turn 1 Solution 2 Graph

31. Your Turn 1 Solution 3 Graph
Control+e to return to the last dialog box

32. Your Turn 1 Solution 3 Graph

33. Your Turn 2
Assume a fair coin is flipped 100 times.
What is the probability of exactly 50 heads?
What is the probability of greater than 60 heads?
Assume a process creates .01 defects per unit. One hundred units were sampled. What is the probability there will be:
Zero defects
Two defects
Find the answers with Minitab

34. Your Turn 2 Solution 1
Calc>Probability Distributions>Binomial
Binomial with n = 100 and p = 0.5
x P( X = x )

35. Control+e to return to the last dialog box
Your Turn 2 Solution 2
Control+e to return to the last dialog box
This will return the probability of 60 or less. Subtract from 1 to get the probability of greater than 60.
Binomial with n = 100 and p = 0.5
x P( X <= x )
The probability of greater than 60 heads is

36. Calc>Probability Distributions>Poisson
Your Turn 2 Solution 3
Calc>Probability Distributions>Poisson
.01 * 100 = 1
Poisson with mean = 1
x P( X = x )

37. Control+e to return to the last dialog box
Your Turn 2 Solution 3
Control+e to return to the last dialog box
Poisson with mean = 1
x P( X = x )

38. Your Turn 3
A Green Belt conducted a gage R&R on a bottling line. He had three operators measure the temperature of the product at 20 locations in the line three times each. He sent the data in Temperature Measurement.mtw. What would you recommend?

39. Your Turn 3 Solution
Assistant>Measurement Systems Analysis

40. Your Turn 3 Solution

41. Your Turn 3 Solution
This is a good measurement system.

42. Your Turn 4
A Green Belt collected data on the fill volumes in cans. The specification limits are to with a target of 12. The data is in six pack spc. What is the capability of this process?

43. Your Turn 4 Solution
Assistant>Capability Analysis

44. Your Turn 4 Solution

45. Your Turn 4 Solution

46. Your Turn 4 Solution
Process control in marginal and capability is poor

47. Your Turn 5
A Green Belt collected data on Gross Line Yield before and after a process change. Did the change make a statistically significant improvement (more is better) on Gross Line Yield? The data is in Gross Line Yield.mtw.

48. Your Turn 5 Solution
Assistant>Hypothesis Test

49. Your Turn 5 Solution

50. Your Turn 5 Solution
He can conclude a statistically significant improvement was made.