Black Belt Process Improvement 2023 (May, June)

You wish to take things to the next level, after following a Green Belt Lean, Six Sigma or Process Improvement Methodologies training, and deepen your knowledge of applicable advanced statistical or Lean techniques? Don’t miss the opportunity & sign up for our Black Belt Process improvement training (Lean Six Sigma). The techniques mentioned below will allow you to zoom in on difficult process & quality problems.

Purpose

We provide insight into the statistical and lean tools that have proven to be of great help in solving everyday problems in an industrial environment:

• Decide whether the results of 2 or more groups (e.g. machines, suppliers, 2 control methods, ...) are different and / or better.
• Find important process variables that can influence the output and the quality of the product and even make predictions about the quality.
• Perform experiments: many people involved in process improvement regularly carry out tests. Over time, "smart" methods such as Design of Experiments have been developed to provide maximum insight into the influence of parameters and their possible interactions on the desired outputs with a limited number of tests. With the new, revolutionary "Definitive Screening Designs" you will really understand what it means to get a maximum of information with a minimum of tests.
• Apply the Lean toolbox in a structured and logic way (avoiding cherry picking).

Target group

This program is focused on those people who have experience in projects and who are involved in the improvement of complex manufacturing or design processes.
Green Belt level is a prerequisite.

Program Six Sigma

• Recap of the basic statistics and extended with statistics used with discrete outputs (good-bad situations).
• The hypothesis tests, both for continuous and for discrete outputs, are practiced and complemented with the non-parametric tests, which are very useful alternatives for classical hypothesis testing (Wilcoxon, Mann-Whitney, Kruskal-Wallis).
• The applications for advanced regression analyses are explained. This includes the combination of discrete and continuous input variables, the non-linear regression and the logistic regression for use with discrete outputs (good-bad situations).
• The Principal Component Analysis is the trigger for Big Data analysis and is used in those many cases where ordinary regression is not allowed or even fails.
• Design of Experiments (DOE), Response Surface Methodology and the top of the bill: the new Definitive Screening Designs that form the bridge between the Screening designs and Optimisation designs. Split plot Designs are explained. These are used when there are so-called Hard-to-Change factors in the experiment.
• Gage R&r or Measurement System Analysis, a special DoE that is used to determine the suitability of a measuring system, is stripped of all its secrecy. The ANOVA type II method used here is also explained.
• The influence of autocorrelation on the calculated control limits is explained in the advanced Statistical Process Control module.

Program Lean

We provide insight into Lean Thinking and the Lean Tools that have proven to be of great help in process optimisation in an industrial environment.

• 5 Lean Principles and different types of wastes
• Value Stream Mapping
  • Current state
  • Manufacturing Critical Time path (MCT)
  • Design future state
  • End-to-End value stream mapping
• Lean toolbox: 5S, visual management, standard work, OEE, Kaizen, SMED, calculating Kanban, line balancing, load levelling,...
• Basic lean statistics
• Demand analysis (product family portfolio, Glenday sieve, ABC-XYZ classification) 
• Advanced lean toolbox: rhythm wheels, S&OP, scenario thinking
• Basics of factory physics and system dynamics

Our approach

• The Black Belt training program consists of 3 work sessions each of 3 consecutive days.
• Each session offers a mix of theoretical foundation and practical exercises.
• Each session offers the opportunity to exchange experiences with other participants.
• At the end of the training, there will be an examination. After succeeding with a final score of 70% or more, the participant will be awarded a “Black Belt Training Certificate”.
• After the training program, it is possible after agreement, to use a project coaching approach, consisting of following elements:
  • Intake discussion to help to select the right project, increasing the chances for success
  • 2 coaching sessions after each training session or ad hoc assistance with data analysis, setting up of DoE, emerging problems etc.
  • Preparation and evaluation of the project story board for certification.

Trainers

Joachim Vermeeren, management consultant, coaches companies in the field of continuous improvement via Lean Manufacturing and Problem Solving. He has a wide background in the automotive industry with in depth knowledge of logistics processes. He is an experienced trainer of Lean Principles and Problems Solving and gathered his knowledge internationally. 

Kurt Maegherman, senior management consultant and Process Improvement Master Black belt, trains and coaches organisations in both the Six Sigma and Lean methodology.   He is experienced in both technical and transactional processes and especially in High Tech industries, the pharmaceutical industry and high volume industries. He has over 10 years of experience as a consultant. He has a Master's Degree in Industrial Electronics Engineering and is a Certified Master Black Belt. He is also a guest lector at ETH Swiss Federal Institute of Technology Zürich 

Tom Van der Straeten, managing partner, senior management consultant, coaches companies and is a professional trainer in the field of Continuous Improvement (Black Belt Lean and Six Sigma), Total Productive Manufacturing and Lean Transformations in the End-to-End Supply Chain. He has experience in production, maintenance and supply chain management in the electronical pharmaceutical, automotive and lighting industries in an international environment as well as in services. He has a Master's Degree in Civil Engineering (Electro Technical Engineering) and has a post gradual degree in Business Administration at the KUL.