Lean Six Sigma Black Belt Workshop





Six Sigma Projects Guided             Online Study Feedback              Six Sigma Experiments           Six Sigma  Conference   
 Job opportunities - SSGBs/SSBBs

 What is Six Sigma? 


      Six Sigma is a rigorous and disciplined methodology that uses data and statistical analysis to measure and improve a company's operational performance by identifying and eliminating "defects" in manufacturing and service-related processes. Commonly defined as 3.4 defects per million opportunities, Six Sigma can be defined and understood at three distinct levels: metric, methodology and philosophy...

       Six Sigma is a customer focused, data driven methodology for achieving real break through success in business. Six Sigma is a comprehensive and flexible system and can be applied to reduce defects, improve designs and process efficiencies.


Why 3Sigma is not enough?

(Is 99.73% (= 3Sigma Performance Level) Really Good Enough?)

Even a three Sigma level company is not good enough, because a 3Sigma level performance means,

* 200,00 lost articles of mail per hour.
* No electricity for almost 7 hours, each month.
* 2 short or long landings at major airports, each day.
* 200,000 wrong drug prescriptions each year.
* Unsafe drinking water almost 15 minutes each day.
* 5000 wrong surgical operations per week.

 (The above information is based on a survey conducted in US)
            Now, can anyone afford to stop at 3Sigma level performance? If a company performs even at 3Sigma level, (that is 99.73% result fall with in the control limits) the above defects are possible. Because of the above cited huge loses, generally many companies go for Six Sigma Implementation Programs/Certification.

 Why you need to do Six Sigma?

          Six Sigma can cut waste and save money. Consider how much money could be saved by eliminating potential defects and the resulting scrap and warranty returns. Time and money may be wasted in corrective actions and delays. Also consider the image those results from product failures for the customer. In order to determine the waste, you need to understand what adds value to your product and what does not.


        One way to know how good you are doing is to compare your operation to similar ones elsewhere, as a benchmark. If there are similar operations in your organization, then bench marking will be easier.


Six Sigma Costs and Savings

One can't expect to significantly reduce costs and increase sales using Six Sigma without investing in training, organizational infrastructure and culture evolution. Sure you can reduce costs and increase sales in a localized area of a business using the Six Sigma quality methodology. For Example,

* Motorola adopted Six Sigma in1987. In 1988, Motorola won its first Baldridge Award.
"Companies of all types and sizes are in the midst of a quality revolution. GE saved $12 billion over five years and added $1 to its earnings per share. Honeywell (AlliedSignal) recorded more than $800 million in savings."

"GE produces annual benefits of over $2.5 billion across the organization from Six Sigma."

"Motorola reduced manufacturing costs by $1.4 billion from 1987-1994."

"Six Sigma reportedly saved Motorola $15 billion over the last 11 years."

 Who  should attend?

            CEOs, Presidents,  Project Managers, Team leaders/Members, Field Staff Members, Project Engineers, Design Engineers, Project Leaders and Administrators, Industrial Engineers, Program Managers, Manufacturing Engineers, Project Coordinators, Operating Managers, Functional Managers, Information Technology Professionals, Software Developers, Quality & Testing Engineers, Sales & Marketing professionals, Civil/Mechanical/Electrical engineers, Procurement specialists, Event mangers, R&D Managers, others involved directly or indirectly with Project Management, Quality assurance managers, BPO team leaders, and Executive leadership from Finance, Training, Communications, Human Resources and Quality who are interested in gaining a better understanding of manufacturing processes and reducing process variability in order to improve business success. This includes:

* Individuals who desire to enhance their professional development with the skills necessary to support Six Sigma projects.

* Employees of companies that have deployed Six Sigma, who work with Black Belts, or who lead their own improvement projects. Companies that want to expand training across a wide range of employees to reduce costs and improve performance

Course Structure (Online):

        All candidates will be awarded IIPMs Six Sigma Black Belt certificate (SSBB) once a candidate meets the following criteria:

1. Studies at least 50 hours online and answers exercises given at the end of the chapters.

2. Passes the IIPMs online Six Sigma Black Belt Exam.

3. Submits any quality improvement (Internal / External) project using relevant quality tools at unit level or function level (Green Belt Level). Necessary sample Green Belt project templates and necessary guidance in GB project completion are provided by IIPM faculty  a part of the Black Belt course.
All Candidates who fulfill the above criteria will be couriered the original Six Sigma Black Belt Certificate free of cost anywhere in the world.

Access to the participants to the online resources is available  for 6 months including the quality improvement  / Green Belt project completion time.  The course is supplied with an end of the course evaluation test of what was learnt and the participants will be supported with excellent templates wherever required.


 All online participants who are PMPs will earn 40 PDUs Certificate towards their CCR once they have completed 40 hours of online study through this PMI approved  course. 
 All online participants can also download a full  (sample actual project) editable project template for their use.

Course fee for online participants:

 * Lean Six Sigma Black Belt Certificate + 40 PDUs Certificate + Six Sigma Black Belt Project Guidance completion certificate / affidavit - US $ 700 only.

Lean SIX SIGMA Black Belt Sample Certificate. Click Here              


Sample Lean SIX SIGMA Black Belt PDUs Certificate. Click Here


Earn 40 PDUs - Click here to see IIPM Courses Approval by  PMI.


Course Completion Exam:

    Open book paper based exam will be conducted on the final day of the course. The exam is conducted to measure the knowledge gained by the participants and to demonstrate the added confidence level out of this course. Candidates have to secure 50% of marks to issue the Black Belt certificate.


Course Structure (Classroom):  

Date:  Click here to see current training schedule.



Course fee for Six Sigma Black Belt Certification - CLASS ROOM:


      Special Offer:
                * Black Belt Certificate  + Black Belt Projects Guidance +
40 PDUs Certificate =  Rs. 27,000 + 10.3% service tax only




Hotel Southern Crest, Venkat Narayana Road, T. Nagar, Chennai-17.      


Sample BB Project Details:


        Please note that the projects for improvement can be from your own company (or) any other company. The projects can address the entire company are small portion (or) part (or) division (or) a small process of a business unit with in the company. The candidates can also suggest project titles from their company for the faculty / instructors / suggestions (or) they can choose any one of the projects available at IIPM. IIPM will facilitate the collection of data and extend support staff services for the project period.  

Practical Hands-on Six Sigma Experiments.

The following practical hands-on experiments will be conducted and guided by Mr. Ari to reinforce the theoretical learning into practical application of six sigma concepts.

1) Mistake proofing (Poke Yoke)
2) Design of Experiments (DOE)
3) Construction of Normal/Binomial Probability curve using a game of chance.
4) Accuracy Vs Precision
5) 5S
6) Reproducibility & Repeatability (Gage R&R)
7) Failure Mode & Effects Analysis (FMEA)

Click here to see Six Sigma Experiments


Six Sigma Projects Guided by IIPM:

1. Case management in Microsoft, Sutherland – A Case study - BPO Industry.

2. Reducing Turn Around Time (TAT) of Production Support Request in Cambridge Solution – A Case study - Manufacturing


3. Reduction of OLA Deviation in CVS processing in SIFY – A Case study - Software Industry.

4. Reduction in Manufacturing of Flanges Production Turn Around Time (TAT)-A Case study-Construction / Fabrication Industry.


Some example projects are below.  


Project 1)  Registration process improvement.

Project 2)  Defects and improvements in Training.

Project 3)  Defects and improvement in online training .

Project 4)  customer Call registration Improvement.

Project 5)  Training course-ware quality improvement.

Project 6)  Admin and maintenance expenses improvement.   



The participants can identify projects in their own organization and implement the DMAIC methodology and show significant improvement in organization. The Students shall review the projects with IIPM on monthly basis. Any questions clarifications can be discussed during the review. Sample project also available for all Online registered participants.


Lean SIX SIGMA Black Belt Certificate:


       This Black Belt certificate will be awarded to all those who have completed the course by passing a test at the end of the course. Please note that ample Flash cards are available to practice for the exam. 

Lean SIX SIGMA Black Belt Sample Certificate. Click Here




      Useful, practical templates and tools are downloadable in our Six Sigma course. These templates are editable and can be modified to suit your company’s requirements.

Salient features of  SSBB course:

       *   Hypothesis Testing – Additional practical examples.

       *   Statistical process control – Details.

       *   Sample size calculations.

       *   DOE (Design of Experiments) in detail with a practical exercise.

       *   Measurement System Analysis – Gage R&R studies.

       *   Learn how to deal with non-normal data.

       *   Hands on practice on Minitab software.

       *   There are excellent career growth opportunities for Black Belts which span across functions and industries.


   Click Here to download the Six Sigma Black Belt Online Course Contents


PART :I-Six Sigma Maturity Assessment

                          This maturity assessment has to be taken after the account activation and prior to start reading the knowledge areas below so as to asses your current level of SSBB awareness/maturity with respect to international standards of Six Sigma.

PART :II-Six Sigma Introduction

Six Sigma : A Primer

Six Sigma Black Belt Body of Knowledge

Six Sigma Black Belt - Lessons

PART :III- Preparing For Deployment

Chapter 1: Enterprise-wide Deployment      
[9 Questions]
Chapter 2: Business Process Management   
[9 Questions]
Chapter 3: Project Management     
[16 Questions]

PART IV: DMAIC Methodology

Chapter 1: DEFINE STAGE        
[15 Questions]

                  1.Project Scope
                  3.Problem Statement

Chapter 2: MEASURE STAGE      
[26 Questions]

                1.Process Analysis and Documentation
                2.Probability and Statistics
                3.Collecting and Summarizing Data
                4.Properties and Applications of Probability Distribution
                5.Measurement Systems.
                6 .Analyzing Process Capability

Chapter 3: ANALYZE STAGE     
[24 Questions]

                1.Exploratory Data Analysis
                2.Hypothesis Testing

Chapter 4: IMPROVE STAGE    
[23 Questions]

               1.Design of Experiment (DOE)
               2.Response Surface Methodology (RSM)
               3.Evolutionary Operations. (EVOP)

Chapter 5: CONTROL STAGE   
[21 Questions]

              1.Statistical Process Control
              2.Advanced Statistical Process Control
              3.Lean Tools for Control
              4.Measurement System Re-Analysis

    [7 Questions]

             Chapter 1: Lean Enterprise
             Chapter 2: Design for Six Sigma (DFSS)


Part: VI - Minitab Application

            Minitab, industry standard statistical software, will be used to demonstrate and apply to many six sigma

            problems through out  the course. This will be a very useful deliverable for later applications and six sigma projects.

PART: VI - Case Studies

             Case Study 1 : Website Response Time
             Case Study 2 : Reducing Helpdesk Turnaround Time
             Case Study 3 : Account Withdrawal Accuracy

PART: VII - Additional Materials

          All classroom participants will be given a CD of full Green Belt editable project template for their use. The CD contains DMAIC stages, simple explanations, some situational case studies, useful templates and Statistics Software. This software useful to calculate sigma levels and to draw Excel charts.

         1. Control Chart

         2. Creating Control Charts Using Microsoft Excel

         3. Editable Project Charter

         4. Editable SIPOC Diagram

         5. Project selection

         6. Sample Size Calculator

         7. Sigma Conversion Table

         8. Six Sigma Sample Questions

         9. Six Sigma Sample Project Report

         10. Downloadable sample Six Sigma BB Project (.pdf)

        11. How to create CONTROL CHART

        12. Sample CONTROL CHART (.xls)

        13. How to Identify Six Sigma Project

        14. Suggested Six Sigma Sample Projects

PART: VIII - Practice E-Cards (Flash Cards)

Flash Cards- E-cards- about 100 excellent Ecards for practicing / exam preparation will be given to each candidate


PART :IX - Templates

1. Sigma Level to DPMO Conversion (.doc)

2. Estimating Sigma Using Long-Term DPMO (.doc)

3. Random Number Generators (.doc)

4. Six Sigma Table (.doc)

5. Difference between Six Sigma & TQM (.doc)

PART :X-Six Sigma Black Belt Final Exam


    Open book paper based exam will be conducted on the final day of the course. The exam is conducted to measure the knowledge gained by the participants and to demonstrate the added confidence level out of this course. Candidates have to secure 50% of marks. The Lean Six Sigma Black Belt certificate will be issued on the final day based on the exam results.


PART: XI - Tips & Traps for the Six Sigma Black Belt Exam

      For Online Course Registration                                                         For Classroom Course Registration