Black Belt Process Improvement - spring 2025

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 exam. After achieving a final score of 70% or more, the participant is awarded a ‘Black Belt Training Certificate’.
• After the training programme, it is possible to make use of a project coaching approach, consisting of the following elements, upon agreement: 
  • Intake interview to help select the right project, increasing the chances of success
  • 2 coaching sessions after each training session or ad hoc help with data analysis, DoE set-up, emerging issues, etc.
  • Preparation and evaluation of the project story board for certification.

More about Stanwick Academy

What can you expect

We provide insight into the statistical 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 logical manner (avoiding cherry picking).

Programme

Programme 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, 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.

Programme Lean 

We provide insight into more technical tools from the lean toolbox that have proven to be of great help in solving everyday problems in an industrial environment:

• Productivity improvements (>20%) in production environments:
  • By installing standard work
  • Through visualisation and load levelling
  • Through line balancing exercises 
• Breakthrough improvements in quality systems through application of Poka Yoke (Zero defects)
• How SMED can substantially (>50%) improve rebuild time, but also how to optimise shutdown (preventive maintenance) using the same methodology.
• Improved supply chain performance (less stock and improved OTIF)
• How do we organise breakthrough improvement ourselves?
• How can we deal with complexity and variation in customer demand and gain a strategic advantage?

Black Belt certification

Participants receive a Black Belt Training Certificate after attending the training and passing the exam. If they want to obtain a Black Belt certificate, they need to carry out an additional process improvement project according to the DMAIC roadmap. Stanwick can guide them in this and after attending the final presentation of the project, the Black Belt certificate will be awarded. Do not hesitate to contact us if you would like more information on this.

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.