Working Hand In Hand...
To Create Your Future
AIT Group
Create the Future
MASTER BLACK BELT TRAINING & CERTIFICATION www.theaitgroup.com
Today’s environment is more competitive and requires more creativity, robustness, and speed
in our responses to our customers. Leading improvement methods to improve competitiveness
include Six Sigma, Lean, Innovation, and Business Process Modeling. To get the best results a
process improvement program today must be multi-dimensional, drawing on Six Sigma, Lean,
and Business Process Models (BPM). Six Sigma training leads to Design for Six Sigma training
which builds capabilities in the innovation area. BPM’s such as Supply Chain Operations
Reference-model (SCOR) provide a more holistic view of how your corporation creates value.
All provide common language and terminology to speed implementation across an enterprise.
All have their place but it is the synergy that brings the greatest results.
Approach
AIT Group believes the framework of a Master
Black Belt’s training will be grounded in the
above methodologies and then supplemented “AIT’s Master Black
with Design for Six Sigma and Advanced Belt training provided
Statistical tools as required by the company’s an outstanding
problem environment, along with Coaching/ foundation for our
Mentoring, Change Management, and expanding Six Sigma
Leadership Development Skills. program which has
resulted in operational
While there is not a pre-determined outline, the and financial gains.”
Master Black Belt training plan will be driven
by a combination of the client’s history with Tim Morrison,
Six Sigma, the gaps revealed by an evaluation, Casa Products
and the client’s goals for the future direction
of organizational problem-solving capabilities
and resources.
After Black Belt certification, an AIT Group Master Black Belt candidate receives an additional
6 months of very focused training in the form of one week sessions, once per month. Similar AIT Group Service Areas
to Black Belt training, all Master Black Belt candidates are required to come to the training
with a project that must be employed through a “Train, Apply and Review” application so COMPETITIVE
that the new tools are learned to be applied. This approach ensures the candidates’ deeper STRATEGY
understanding of the Six Sigma tool fundamentals. In parallel, during the first four sessions, & INNOVATION
candidates will practice teach the AIT Black Belt Curriculum while receiving detailed coaching
from the AIT MBB. In addition, candidates will be taught new advanced modules from the AIT
Group Master Black Belt. VAluE &
OPPORTuNITY
Accelerating Business Benefits: IdENTIFICATION
The Master Black Belt is the highest level of mastery of the tools, techniques, and concepts
associated with Six Sigma. The Master Black Belt operates as the internal quality consultant,
coaches teams, provides tutorials, and facilitates meetings with both project teams and
executives. VAluE CHAIN
TRANSFORMATION
The AIT Group’s Master Black Belt Certification provides resources with the necessary
technical and strategic skills to assist the executive leadership team with their Lean Six Sigma
responsibilities.
lEAN SIx SIGMA
This includes aiding the executives in reaching their financial goals by proper project selection, & dFSS dEPlOYMENT
candidate selection and change management. Change management is a crucial element that
contributes to the success of the Six Sigma effort within an organization. Master Black Belts
are leaders in the change management process. North America - Mexico - Europe - China - India - Korea
Working Hand In Hand...
To Create Your Future
AIT Group
Create the Future
MASTER BLACK BELT TRAINING & CERTIFICATION www.theaitgroup.com
Master Black Belt Overview
Objectives Methodology Deliverables
• Quickly transition Green Belt training and coaching • Trained to develop a deeper understanding • Establishment of internal
• Ultimately transition Black Belt training and of fundamental Lean Six Sigma tools and experts to lead future deploy-
coaching individual specialization areas (DFSS, R&D, ments
• Provide expert resources to support self-sustain- Transactional, etc.) • Creation of customized In parallel, during the
ing Lean Six Sigma program • Training and facilitation practice is built into materials first four sessions,
• Create customized materials for future internal all six sessions
training efforts • Candidates develop material for future inter-
candidates will practice
nal training demonstrating expert abilities teach the AIT Master
Black Belt Curricula
Master Black Belt Course Content while receiving detailed
coaching from the
Course Content Course Content AIT MBB. In addition,
Week One introduces the candidates to adult learning styles and training Week Two covers Experimental Design in depth, getting into more of the candidates will be taught
techniques. Candidates teach Black Belt modules and receive real-time
feedback on technical knowledge and teaching ability. Practical, graphical,
theory behind the analysis and the practical application of this powerful tool.
Candidates will work on homework designed to enhance their knowledge of new advanced modules
Week 2
Week 1
and analytical application of each tools is discussed in detail the toolset and practice teach the material to continue to develop that ability.
TOPICS COVeReD IN THIS SeSSION INCLUDe:
from the AIT Group
TOPICS COVeReD IN THIS SeSSION INCLUDe: The Philosophy and Concepts of DOE Master Black Belt.
Thought Process Mapping Process Mapping Execution of Full and Fractional DOE’s
Failure Modes and Effects Analysis Measurement System Evaluation Minitab Training/ Team Training Exercises
Numerical Evaluation of Metrics Message Map Hunter and Hunter Fully Nested ANOVA
Presentation Skills Review Effective Teams Pooling—Daniel’s Method
MBB Regression and MBB ANOVA
Factor Relationship Diagrams
Change Leadership For more information
on the AIT Group’s
Course Content Course Content Master Black Belt Training
Course Content
Week Four focuses on regression analysis and other advanced statistical
service please call:
Week Three exposes the Master Black Belt candidate to the Lean toolset
and how its integration with Six Sigma enhances the practitioner’s ability tools and their relationship to designed experiments. The candidates will
Week 4
to produce significant, long lasting results. have the opportunity to practice their DOE techniques in a continuation of
888-826-2484
Week 3
the exercise from Week 2
TOPICS COVeReD IN THIS SeSSION INCLUDe: TOPICS COVeReD IN THIS SeSSION INCLUDe:
Value Stream Mapping Product Flow Regression Analysis/ Attribute Regression
Employee Activity / Standard Work Setup Reduction Components of Variation (COV)
Workplace Design Total Productive Maintenance Chi Squared Test for Independence
Visual Workplace Communication Strategies Adv. DOE Topics & Experiment Case Studies
Rank Transformation
Exp. w/ Attribute Data as a Response
Team Training Exercise
Course Content Course Content
Course Content
Week Five focuses on Design for Six Sigma (DFSS). Approximately 80% of Week Six tests one of the attributes of a great Master Black Belt, which
the cost of a product is determined in the design stage. Candidates learn is the ability to take a highly complex topic and explain it in a layperson’s
DFSS techniques and Response Surface Methods (RSM) using the Box terms. Each candidate will develop and deliver a Black Belt module on a
Helicopter. A proposal is prepared by each team and presented to manage- topic that is new to them. Resources from the internet, text books, and
Week 6
Week 5
ment which contains the actions and timing required to launch DFSS in Minitab may be used.
their organization.
TOPICS COVeReD IN THIS SeSSION INCLUDe: TOPICS COVeReD IN THIS SeSSION INCLUDe:
Design Scorecard Time Series Analysis
Response Surface Methodology Developing ARIMA methods for Modeling Auto-Correlated
Requirements Flow Down Data
Modeling Sensitivity Intro to Advanced Tools
SCOR Overview; Statistical Tolerancing Advanced Topic Modules
Program Phase
Mixture Designs; Process Control
The final two sessions enable development of individual Master Black Belt candidate specialization and mastery. The fifth
session focuses on more advanced modules and “Mastery Reviews”. The Mastery Reviews enable instructors to become self
sufficient to train without presentation aids. Once the candidate has mastered the Mastery Reviews the candidate will have
the capability to teach any topic without prepared material. The Master Black training concludes with the sixth session where
candidates present an advanced module they have researched and prepared. All this is combined with coaching and mentoring
by the AIT MBB instructor. After the training and project is completed a board of three Master Black Belts convene to review
the candidate’s qualifications for certification.
Delivering Tomorrow’s Results Today
Experience: The AIT Group has been delivering accelerated business benefits in Aerospace, Automotive, Consumer Products,
Chemical, Construction, Medical, and Distribution Industries. The AIT Group has the expertise to allow companies of all sizes
to take advantage of the benefits of training. The AIT Group facilitated projects exceed traditional returns, frequently exceeding
1 million dollars in savings...an outstanding training investment.
This document contains three sections, the minimum Master Black Belt certification
criteria, typical Master Black Belt projects, and typical Master Black Belt roles and
responsibilities. The AIT Group Master Black Belt program is designed to prepare you
for these roles and responsibilities.
Master Black Belt Certification Criteria
• Complete six sessions of Master Black Belt training
o Complete any “needs improvement” issues noted by instructor(s) and
students. Feedback will be given daily.
• ** Teach one wave of Black Belt training
o Complete any “needs improvement” issues noted by instructor(s) and
Black Belt students
• Lead one wave of Green Belt training.
• Mentor three Black Belts through certification.
• Develop a New Black Belt training module
o MBB instructor will approve module selection
• Demonstrate the following tool usage and understanding at a MBB level.
o Thought Process Map
o Process Map
o FMEA
o NEM
o MSE (Kappa, ICC / continuous)
o Demonstrate a statistical difference has been made using regression,
DOE, statistical tests and ANOVA
o Control Plan
o Identify Y=f(x) equation in Black Box experiment.
• Successfully complete Technical Certification requirements
o Successful presentation of “Mystery Modules”
o Successful Create and delivery of New BB training module
o Complete all Details in MBB Certification Tracker
• Obtain satisfactory results from projects selected by you and your Champion:
• Champion’s approval of candidate which includes $$$ savings goals, leadership
skills, behavior, impact, etc.
**An opportunity exists to reduce the amount of teaching time for certification. The
reduction depends on how many MBB candidates we have in our class and how many
waves of Black Belt training are active during our MBB session.
Please contact me, at cell phone 915-487-1816, or AIT office 915-613-3885, if you have
any questions.
Thanks,
Bruce Rohn
Master Black Belt / Instructor
AIT Group, Inc.
Composite Wave 7
MBB Project Attributes:
An MBB project should have an overarching theme that is strategic in nature and targeted
at the heart of your business improvement objectives. Great projects focus on common
cause issues rather than special cause issues. A project directly linked to a VP’s
objectives should stand the test of time. The perfect MBB project contains many of the
following activities:
• Work with executives in strategic planning sessions to create divisional goals
• Identify the opportunities to reach the goals
• Break the opportunities into logical projects
• Validate financial opportunity for each project
• Determine leadership and team members to complete the project
• Identify key BB’s/BBC’s/GB’s to lead each project
• Ensure teams are deployed properly and supported by the organization
• Mentor management, BB’s and GB’s to ensure the problem is solved correctly
using the six sigma tools outlined in the certification document
• Insure a control plan is in place to sustain the gains.
• Verify the savings is realized, revenue is achieved or cost is avoided.
• Examples of good MBB projects
o Reduce COPQ at division X by Y%.
o Increase Yield on product line X by Y%
o Improve margin at division X by Y%
o Avoid the purchase of X million dollars of capital equipment by
improving the throughput of the current machinery on Product line X.
o Reduce new product design cost by Y%
o Reduce Divisional inspection and test by Y% to reduce cycle time.
o Identify and implement a production method which avoids a costly
process step
o Transform an unprofitable division to a profitable division.
o Reduce customer returns/complaints by Y%
o Reduce software rework/inspection time by Y%
MBBC project savings should be above $500,000 dollars. After certification, an MBB
should be responsible for two to ten million dollars of savings per year. The savings
amount is the sum of the individual team’s savings the MBB directly supports. Some
projects are difficult to place a dollar value on. For example, transitioning product from
site X to site Y. The transition needs to be done correctly, but it is difficult to accurately
identify the savings. Transition Projects are better suited for a certified MBB than one
who is working through the certification process because of the daily attention required.
Poor utilization of an MBB is characterized by a disproportionate amount of time
working on activities such as ad-hoc statistical support, analysis of historical data, and
daily firefighting.
2 Composite Wave 7
Typical Roles and Responsibilities of an MBB
Each color represents an excerpt from an individual job posting.
Duties are to support the Director of Six Sigma in the development and
implementation of a business process transformation strategy to enable substantial
and continuous improvement in the ability to satisfy customer demands. To support
planning and facilitation of Six Sigma Workshops and Projects using appropriate tools
to ensure the Division has a high added value framework for all its business process
transformation work. To support the Director of Six Sigma in the drive toward a
process knowledge management system and inter-BU / inter-divisional transfer of
best practice processes. To advise and coach management on all aspects of Six
Sigma Implementation and to promote a consistent understanding of Six Sigma
amongst all employees. To discover / propose new applications for Six Sigma by
constantly upgrading knowledge of the methodology and tools. MBA a plus with a
minimum of an Engineering, Science or Business Degree. Minimum of 8 years of
design, supervisory and /or operational experience, preferably in a railway
environment. Knowledge of "best practice" business process approaches and tools.
Significant experience of developing and implementing process improvement
strategies. Knowledge of benchmarking, Six Sigma and cost benefit analysis.
-Support and mentor for 8-12 Six Sigma Black Belts.
-Work with Quality and Process Improvement Manager to generate Six Sigma
opportunity assessments and rollout plans.
-Provide strong project selection and project scoping skills to senior staff.
-Provide initial expertise for Six Sigma project selection, ensuring projects link with
key business objectives and can deliver substantial financial payback.
-Educate, and enable the organization to fully implement Six Sigma across all
processes and geographies.
-Train and mentor Black Belts. Coach and consult on Black Belt projects.
-Provide key process identification tools, key process and sub-process dashboard
creation, execution and validation.
·Assist in developing and deploying Six Sigma Company wide
·Drive change at all organization levels to instill customer focus, process ownership
and data driven decision-making.
·Mentor executive management, the Project Champions, Process Owners, Black
Belts, Green Belts, and the entire Improvement team.
·Coordinate integration of Six Sigma with Lean, e-biz, core business, and support
processes.
·Assist process owners/leadership in identifying process improvements, quantifying
benefit.
·Project work
·Eventually this position will spend a % of its time training in-house GB’s and BB’s
*You will organize, train, structure, and mentor Black Belts in order to achieve
desired business results
3 Composite Wave 7
Responsible for providing technical (quality tool) and statistical expertise to Black
Belts as required
*Measures and provides data to demonstrate successful completion of the chartered
process improvement project
*Assist Black Belts in developing and tracking appropriate output and process
metrics necessary to demonstrate the improvement toward established goals
*Make final decisions on approaches for applying statistical measures and methods
specific Black Belt projects
Integrate Six Sigma concepts• & tools into all business units.
Train,• coach, develop, and certify Black Belts; provide on-site support to Black
Belts
Be advanced users and teachers of Six Sigma tools and methods•
• Educate GM’s and leadership in Six Sigma strategy and benefits to the business
Develop and enhance training materials for Black Belts and Green• Belts
Manage Green Belt development process•
Write and extract case• studies to be used in training additional Black Belts
Work with business• unit Six Sigma Steering Committees & Champions to establish
project goals, strategies, & priorities
Help develop and coordinate planning and• execution of Six Sigma cost savings
initiatives
Coordinate Six Sigma• efforts and information within Office Products. Fasson, and
Converting
All• other duties as assigned within Corporate Manufacturing & Engineering
4 Composite Wave 7