PROJ08021 2019 Project Six Sigma Black Belt

General Details

Full Title
Project Six Sigma Black Belt
Transcript Title
Project Six Sigma Black Belt
N/A %
Subject Area
PROJ - Project
MENG - Mech. and Electronic Eng.
08 - NFQ Level 8
10 - 10 Credits
Start Term
2019 - Full Academic Year 2019-20
End Term
9999 - The End of Time
Caroline Mullan, Brian Coll
Programme Membership
SG_ELEAN_E08 202000 Level 8 Certificate in Engineering in Advanced Lean Sigma Quality (Project) SG_EADVA_E08 201900 Level 8 Certificate in Engineering in Advanced Lean Sigma Quality SG_EQLTY_K08 201900 Bachelor of Science (Honours) in Engineering in Quality Management and Tech

The project aims to provide students with the opportunity to apply and integrate the skills and knowledge they have gained on the Quality modules they are studying. These modules are Statistics, SPC, Experimental Design and Quality Management.

The student should bring the learning from the modules covered in the course to identifying and leading six sigma projects within their organisation.  Black Belts are the leaders in creating project teams, training and mentoring these teams and driving a culture of continuous process improvement within their organisation.  A mentor will be assigned to each project.

The mentor will act as a guide in agreeing the relevance, and scope of the project, and monitor the progress on a regular basis. Updates will be sent to the mentor on an agreed basis.

Note: For external *ASQ Six Sigma Black Belt certification, ASQ requires two completed projects with signed affidavits or one completed project with signed affidavit and three years of work experience in one or more areas of the Six Sigma Body of Knowledge.

Learning Outcomes

On completion of this module the learner will/should be able to;


Identify a problem which needs to be addressed of importance to the organisation.


Lead the Six Sigma project meeting the goals of Time, Financial Savings and Requirements.


Utilise the Six Sigma DMAIC structured approach to manage the project. Apply appropriate Lean and Six sigma statistical tools in reducing process variation, optimising the process and realising financial savings.


Prepare a written report which outlines in detail the background to the project, a literature review outlining current knowledge in the project area, the methodology used to address the problem, discussion, conclusions and recommendations.


Present project results with Executive Summary, Conclusions and Recommendations and discuss the approach taken and results achieved.

Teaching and Learning Strategies

The online teaching and learning strategy will follow the guidelines as developed by Quality Matters:

Unique to the Quality Matters Rubric is the concept of alignment. This occurs when critical course components - Learning Objectives (2), Assessment and Measurement (3), Instructional Materials (4), Learner Interaction and Engagement (5), and Course Technology (6) - work together to ensure students achieve desired learning outcomes.

Module Assessment Strategies

The Project will be assessed by the student preparing interim and final written reports along with a presentation by the student. The project supervisor may also require a log book to be completed regularly by the student.

Project: Six Sigma Black Belt DMAIC

The Interim Report and Final Report are to be prepared in a structured format using Microsoft Word. The Final report should be at least 5000 words (20pages) and contain the following major sections.

  • Executive Summary
  • Introduction
  • Literature Review
  • Background & Objectives
  • Method (DMAIC)
  • Results
  • Conclusions & Recommendations

Six Sigma Projects will be assessed taking into consideration the following:

1. Report Structure & Format

  • How clear were the aims and objectives?
  • Is the report well structured with logical flow and
  • Was supporting data available
  • Good use of charts and graphs

2. Students contribution

  • Individual Vs Team contribution
  • How critical was the student to success of overall project?

3. Problem solving methodology used

  • Was methodology appropriate to this project?
  • How many tools were used? - Six Sigma, Lean, Project Management, etc.
  • Should additional tools have been chosen?

4. Value to the company

  • Did the project meet its goals?
  • What metrics were improved?
  • How much money, time was saved, quality improved?

5. Level of innovation and technical difficulty

  • How innovative were the solutions proposed?
  • How technically difficult was the project?
  • Was the project complex, cross-functional?

Repeat Assessments

Repeat Project / Assessments

Indicative Syllabus

Syllabus Content

  • The student should bring the learning from the subjects covered in the course to conceive, define and agree a project which is appropriate to the Black Belt standard.

Six Sigma DMAIC - Black Belt Project

The Six Sigma black belt project will be undertaken by the student and should address a substantive issue in the workplace. The project will test the student's ability to define a real-life problem of concern to the organisation, design a strategy for addressing the problem, gather data, formulate and evaluate options and make recommendations. The project should follow the Six Sigma DMAIC methodology. It is important that the student leads the Black Belt project and makes a significant contribution to the success of the project. A financial saving must be identified. The Black belt is normally expected to contribute annualised savings from €50,000 - €100,000. The amount of savings will depend on the size of the company, sales revenue, number of employees and opportunities for improvements.

The Six Sigma project will also cover the following areas:

1. Project management basics

•· Project charter and problem statement

•· Define and describe elements of a project charter and develop a problem statement, including baseline and improvement goals.

•· Project scope

•· Assist with the development of project definition/scope using Pareto charts, process maps, etc.

•· Assist with the development of primary and consequential metrics (e.g., quality, cycle time, cost) and establish key project metrics that relate to the voice of the customer.

•·  Use project tools such as Gantt charts, critical path method (CPM), and program evaluation and review technique (PERT) charts, etc.

•· Provide input and select the proper vehicle for presenting project documentation (e.g., spreadsheet output, storyboards, etc.) at phase reviews, management reviews and other presentations.

•· Describe the purpose and benefit of project risk analysis, including resources, financials, impact on customers and other stakeholders, etc.

  • Describe the objectives achieved and apply the lessons learned to identify additional opportunities.

 2. Team dynamics and performance

•·  Define and describe the stages of team evolution, including forming, storming, norming, performing, adjourning, and recognition. Identify and help resolve negative dynamics such as overbearing, dominant, or reluctant participants, the unquestioned acceptance of opinions as facts, groupthink, feuding, floundering, the rush to accomplishment, attribution, discounts, plops, digressions, tangents,

•· Describe and define the roles and responsibilities of participants on six sigma and other teams, including black belt, master black belt, green belt, champion, executive, coach, facilitator, team member, sponsor, process owner, etc.

•· Define and apply team tools such as brainstorming, nominal group technique, multi-voting, etc.

•· Use effective and appropriate communication techniques for different situations to overcome barriers to project success.

Coursework & Assessment Breakdown

Coursework & Continuous Assessment
100 %

Coursework Assessment

Title Type Form Percent Week Learning Outcomes Assessed
1 Project Proposal Project Written Report 5 % Week 2 1
2 Formative and Summative Assessment Continuous Assessment Assessment 25 % OnGoing 2
3 Written Report Interim Report Continuous Assessment Project 20 % Any 1,2,3,4
4 Written Report Final Report / Presentation Continuous Assessment Project 50 % End of Term 1,2,3,4,5

Part Time Mode Workload

Type Location Description Hours Frequency Avg Workload
Tutorial Online Mentoring 0.25 Weekly 0.25
Total Part Time Average Weekly Learner Contact Time 0.25 Hours

Online Learning Mode Workload

Type Location Description Hours Frequency Avg Workload
Online Lecture Online Theory 1 Twice Per Semester 0.13
Total Online Learning Average Weekly Learner Contact Time 0.13 Hours

Module Resources

Non ISBN Literary Resources

Recommended Reading 





The Six Sigma Handbook, Third Edition

Thomas Pyzdek and Paul Keller

McGraw-Hill Professional

  • ISBN-13: 978-0071623384



  Project Management : The Managerial Process

Gray, Clifford F.


Boston : McGraw-Hill/Irwin.


The Certified Six Sigma Black Belt Handbook, Second Edition

T.M. Kubiak and Donald W. Benbow


ASQ Press

  • ISBN: 978-0-87389-732-7


 Six Sigma Demystified 2nd Edition 

Paul A. Keller


McGraw-Hill Professional



Journal Resources

Listed on Moodle course page

URL Resources

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Other Resources

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Additional Information

Listed on Moodle course page