Lean Six Sigma Certification Exam Preparation Guide based on IASSC Black Belt Body of Knowledge

Lean Six Sigma Training Guide (sixsigmatrainingfree.com) is a free study guide for Lean Six Sigma Green Belt and Black Belt certification exams. It follows the IASSC Black Belt Body of Knowledge and links each topic, from DMAIC and the 8 wastes to hypothesis testing and control charts, to a study page, with free practice exams and statistical tables.

Lean Six Sigma Body of Knowledge — start with the 8 wastes, 5S, SIPOC, value stream mapping, Kaizen, and poka-yoke, and follow the tools in learning order on this site.

If you are planning to take a Lean Six Sigma Black Belt exam and researched internet and realized that Six Sigma certification training courses are too pricey and study materials are not within your budget either, then HERE is a Solution. I would like to share this free lean six sigma training guide which will help you prepare for the International Association for Six Sigma  (IASSC) Lean Six Sigma Certification Exam. The six sigma training guide below includes links covering IASSC version of Lean Six Sigma Body of Knowledge. Good Luck!

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This guide will help IASSC Lean Six Sigma Black Belt candidates prepare for a certification exam for FREE. Although this guide is based on the IASSC Lean Six Sigma Black Belt BOK, it will still be useful for candidates seeking lower belt (green belt, yellow belt) certifications.

About International Association for Six Sigma Certification (IASSC)

The International Association for Six Sigma Certification (IASSC) is a Professional Association dedicated to growing and enhancing the standards within the Lean Six Sigma Community. IASSC is the only independent third-party certification body within the Lean Six Sigma Industry that does not provide training, mentoring and coaching or consulting services. IASSC exclusively facilitates and delivers centralized universal Lean Six Sigma Certification Standards testing and organizational Accreditation’s.

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IASSC Lean Six Sigma Training Guide

1.0 Define Phase

1.1 The Basics of Six Sigma
1.1.1 Meanings of Six Sigma

• Body of Knowledge
• Body of Knowledge
• http://www.skymark.com/resources/methods/sixsigmaquality.asp

1.1.2 General History of Six Sigma & Continuous Improvement

• General History of Six Sigma and Continuous Improvement
• http://www.todaysengineer.org/2010/dec/six-sigma.asp

1.1.3 Deliverables of a Lean Six Sigma Project

• http://www.sixsigmatraining.org/tag/project-deliverables

1.1.4 The Problem Solving Strategy Y = f(x)

• http://www.isixsigma.com/new-to-six-sigma/dmaic/yfx-roadmap-telling-dmaic-story-using-xs-and-ys/
• Big Y

1.1.5 Voice of the Customer, Business and Employee

• http://www.six-sigma-material.com/Voice-of-the-Customer.html

1.1.6 Six Sigma Roles & Responsibilities

• Six Sigma Belt Roles and Responsibilities
• http://www.isixsigma.com/new-to-six-sigma/roles-responsibilities/six-sigma-roles-and-responsibilities/

1.2 The Fundamentals of Six Sigma
1.2.1 Defining a Process
1.2.2 Critical to Quality Characteristics (CTQ’s)

• http://www.visionraval.com/six-sigma-critical-to-x-overview/
• http://www.isixsigma.com/dictionary/critical-to-quality-ctq/

• http://www.processma.com/resource/critical_to_quality.php
• http://www.mindtools.com/pages/article/ctq-trees.htm (CTQ tree)
• http://video.mit.edu/watch/lecture-4-quality-function-deployment-qfd-and-house-of-quality-12209/ (Quality Function Deployment_video)
• http://gurujuran.blogspot.com/2009/04/jurans-trilogy.html (Juran’s quality trilogy: quality planning, quality control, and quality improvement)

1.2.3 Cost of Poor Quality (COPQ)

• http://www.isixsigma.com/implementation/financial-analysis/cost-quality-not-only-failure-costs/
• www.juran.com/elifeline/elifefiles/2009/09/Cost-of-Poor-Quality.ppt
• http://www.six-sigma-material.com/Cost-of-Poor-Quality.html
• http://asq.org/learn-about-quality/cost-of-quality/overview/overview.html (Cost of Quality)
• http://www.systemsquality.com/sitebuildercontent/sitebuilderfiles/coqascidriver.pdf
• http://asq.org/learn-about-quality/qfd-quality-function-deployment/overview/kano-model.html (Kano Model)

1.2.4 Pareto Analysis (80:20 rule)

• Pareto analysis
• http://www.mindtools.com/pages/article/newTED_01.htm

1.2.5 Basic Six Sigma Metrics
a. including DPU, DPMO, FTY, RTY Cycle Time, deriving these metrics and these metrics

• Basic Lean Six Sigma Metrics

Read more:

• http://www.six-sigma-material.com/defectsperunit.html (DPU)
• http://www.six-sigma-material.com/defectsperopportunity.html (DPO)
• http://www.six-sigma-material.com/defectspermillionopportunities.html (DPMO)
• http://en.wikipedia.org/wiki/First_pass_yield (FTY vs TPY)
• http://www.six-sigma-material.com/Final-Yield.html (FY)
• http://www.six-sigma-material.com/Throughput-Yield.html (TPY)
• http://www.six-sigma-material.com/Rolled-Throughput-Yield.html (RTY)
• http://lssacademy.com/2010/07/20/how-to-determine-cycle-time-takt-time-lead-time/(Cycle Time and Takt Time)

1.3 Selecting Lean Six Sigma Projects
1.3.1 Building a Business Case & Project Charter

• http://www.managementstudyguide.com/business-case-for-project.htm (Business Case)
• http://www.managementstudyguide.com/assembling-project-charter.htm (Project Charter)

1.3.2 Developing Project Metrics

• http://www.managementstudyguide.com/what-are-metrics.htm (What are metrics)
• http://www.managementstudyguide.com/primary-metric.htm (Primary metrics)
• http://www.managementstudyguide.com/secondary-metric.htm (Secondary metrics)
• http://www.isixsigma.com/methodology/balanced-scorecard/develop-correct-six-sigma-project-metrics/

1.3.3 Financial Evaluation & Benefits Capture

• http://www.managementstudyguide.com/measuring-financial-benefits-of-six-sigma.htm
• http://www.mathsisfun.com/money/net-present-value.html (PV, FV and NPV)
• http://books.google.com/books?id=yL7MBbUbKQQC&pg=PA32&lpg=PA32&dq=financial+measures+roi+npv+margin+six+sigma&source=bl&ots=vc02tFvRED&sig=41AyTeGBGBLrcnVdJiVHqtV2KrE&hl=en&sa=X&ei=9vKoUe0LkajQAcaxgKAH&ved=0CDIQ6AEwAQ#v=onepage&q=financial%20measures%20roi%20npv%20margin%20six%20sigma&f=false
• http://www.mathsisfun.com/money/net-present-value.html (PV, FV and NPV)

1.4 The Lean Enterprise
1.4.1 Understanding Lean

• http://leanmanufacturingtools.org/39/lean-thinking-lean-principles/  
• http://leanmanufacturingtools.org/71/muda-mura-and-muri-lean-manufacturing-wastes/

1.4.2 The History of Lean

• http://www.lean.org/WhatsLean/History.cfm 
• http://www.strategosinc.com/just_in_time.htm

1.4.3 Lean & Six Sigma
Body of Knowledge
1.4.4 The Seven Elements of Waste
a. Overproduction, Correction, Inventory, Motion, Overprocessing, Conveyance, Waiting.

• The 8 wastes (TIMWOODS)
• The 8 wastes (TIMWOODS)
• http://www.lean.org/Common/LexiconTerm.aspx?termid=324&height=550&width=700

1.4.5 5S
a. Straighten, Shine, Standardize, Self-Discipline, Sort

• 5S 
• http://en.wikipedia.org/wiki/5S_(methodology)

2.0 Measure Phase
2.1 Process Definition 
2.1.1 Cause & Effect / Fishbone Diagrams 

• http://en.wikipedia.org/wiki/Ishikawa_diagram

2.1.2 Process Mapping, SIPOC, Value Stream Map

• http://www.six-sigma-material.com/Process-Maps.html (Process map) 
• http://www.dummies.com/how-to/content/how-to-break-down-process-flow-for-a-six-sigma-ini.html (Process map)
• http://www.breezetree.com/article-excel-flowchart-shapes.htm (Detailed process mapping)
• SIPOC diagrams (SIPOC)
• http://www.nwlean.net/toolsCD/VSM/4%20steps%20to%20VSM.pdf (VSM)

2.1.3 X-Y Diagram

• http://www.six-sigma-material.com/Correlation-Matrix.html
• http://books.google.com/books?id=Yi7wpnL6kh0C&pg=PA92&lpg=PA92&dq=xy+matrix+diagram+six+sigma&source=bl&ots=boQQ3c0EAD&sig=yKMP5flZbwjfFl2JeV_uuRPR6Sk&hl=en&sa=X&ei=s3RtUbuOHofe4AP8ooC4Bw&sqi=2&ved=0CFsQ6AEwBw#v=onepage&q=xy%20matrix%20diagram%20six%20sigma&f=false

2.1.4 Failure Modes & Effects Analysis (FMEA) 

• Failure Modes and Effects Analysis with video tutorial
• http://www.isixsigma.com/tools-templates/fmea/quick-guide-failure-mode-and-effects-analysis/

2.2 Six Sigma Statistics
2.2.1 Basic Statistics

• http://www.six-sigma-material.com/Data-Classification.html (Data classification)
• Descriptive vs. inferential statistics

2.2.2 Descriptive Statistics

• http://www.six-sigma-material.com/Central-Tendency.html (Measures of central tendency)
• http://www.six-sigma-material.com/Measures-of-Dispersion.html (Measures of dispersion)

2.2.3 Normal Distributions & Normality

• Normal distribution
• http://www.qimacros.com/hypothesis-test/data-normality-test/ (Normality test)
• http://people.richland.edu/james/lecture/m170/ch12-int.html (Chi squared distribution)
• Chi-square distribution table (Chi squared distribution)
  
• http://people.richland.edu/james/lecture/m170/ch13-f.html (F distribution)
• Lognormal distribution
• Weibull distribution

2.2.4 Graphical Analysis

• http://processma.com/resource/graphical_analysis.php 

2.3 Measurement System Analysis
2.3.1 Precision & Accuracy

• Measurement system analysis (MSA) and Gage R&R

2.3.2 Bias, Linearity & Stability

• Measurement system analysis (MSA) and Gage R&R

2.3.3 Gage Repeatability & Reproducibility

• Validating a measurement system with a Gage R&R study
• http://www.pdfsixsigma.com/support-files/2.3.4_Variable_and_Attribute_MSA.pdf
• http://www.conceptmachine.com/files/zeiss/GR&R%20Studies.pdf
• http://www.micquality.com/six_sigma_glossary/precision_tolerance_ratio.htm (P/T)

2.3.4 Variable & Attribute MSA

• R&R analysis for attribute measurements
• Kappa

2.4 Process Capability
2.4.1 Capability Analysis

• Process capability analysis (Cp, Cpk, Pp, Ppk)
• http://www.clothingtraining.org.hk/webpage/hkrita-psm/TrainingMaterials/Process%20Capability.pdf
• Cp, Cpk, Pp, and Ppk: what the values mean and when to use each

2.4.2 Concept of Stability

• Control charts

2.4.3 Attribute & Discrete Capability

• http://statisticaloutsourcingservices.com/Capability.pdf

2.4.4 Monitoring Techniques

• See Statistical Process Control

3.0 Analyze Phase
3.1 Patterns of Variation

• https://www.isixsigma.com/topic/positional-cyclical-and-temporal-variation/
• Positional (within unit/sample), Cyclical (part to part) and Temporal (time to time)

3.1.1 Multi-Vari Analysis

• http://www.sixsigmaonline.org/Flash_Videos/Supplemental/Printable/08_multivari.pdf

3.1.2 Classes of Distributions

• Statistical distributions

Discrete distributions:

• Binomial distribution
• Poisson distribution
• Hypergeometric distribution

Continuous distributions:

• Uniform distribution
• Exponential distribution
• T student distribution
• Non-normal distributions
• http://www.minitab.com/en-US/training/tutorials/accessing-the-power.aspx?id=1706&lang (Identify data distribution with minitab)

3.2 Inferential Statistics
3.2.1 Understanding Inference

• http://www.sixsigmadaily.com/terms/inferential-statistics

3.2.2 Sampling Techniques & Uses

• http://www.six-sigma-material.com/Samples.html
• Sampling methods
• Determine sample size
• More about sampling

3.2.3 Central Limit Theorem

• Central Limit Theorem
• Central limit theorem
• Central limit theorem

3.3 Hypothesis Testing
3.3.1 General Concepts & Goals of Hypothesis Testing

• https://www.google.com/url?sa=t&rct=j&q=&esrc=s&source=web&cd=2&cad=rja&ved=0CDIQFjAB&url=http%3A%2F%2Fwww.opensourcesixsigma.com%2Fv%2Fvspfiles%2Fassets%2Fimages%2Fsample%2520-%2520lss%2520black%2520belt%2520course%252010.ppt&ei=2qmwUcq0OKLE0QHlpYCIDA&usg=AFQjCNFpkDg-OUoSuzjN0ojFtU7xu8R3hA&bvm=bv.47534661,d.dmQ

3.3.2 Significance; Practical vs. Statistical

• Hypothesis testing in Six Sigma

3.3.3 Risk; Alpha & Beta

• See 3.3.1
• Alpha and beta risks
• Power 1-Beta
• https://www.google.com/url?sa=t&rct=j&q=&esrc=s&source=web&cd=2&cad=rja&ved=0CDIQFjAB&url=http%3A%2F%2Fwww.opensourcesixsigma.com%2Fv%2Fvspfiles%2Fassets%2Fimages%2Fsample%2520-%2520lss%2520black%2520belt%2520course%252010.ppt&ei=2qmwUcq0OKLE0QHlpYCIDA&usg=AFQjCNFpkDg-OUoSuzjN0ojFtU7xu8R3hA&bvm=bv.47534661,d.dmQ (Sampling and power)

3.3.4 Types of Hypothesis Test

• Parametric vs. non-parametric tests
• Choose a hypothesis test

3.4 Hypothesis Testing with Normal Data

• Decision tree
• Hypothesis testing with Normal Data decision tree

3.4.1 1 & 2 sample t-tests

• One sample Z test
• Z-score tables (Z score and other statistical tables)
• Z-score tables (Z score calculator)
  
• One sample T test
• t-distribution table (T score table)
• Two sample Z test for comparing two means
• Two-sample t test (Two sample T test for comparing two means / DF for separate s: the smaller of n 1– 1 and n 2– 1 DF for pooled s: df = n 1+ n 2– 2)
• Why to pool variances
• Paired T test

3.4.2 1 sample variance

• Chi squared test for the variance
• F test for Equality of two variances

3.4.3 One Way ANOVA

• One-way ANOVA
• http://www.psychstat.missouristate.edu/introbook/sbk27.htm (ANOVA detailed)

a. Including Tests of Equal Variance, Normality Testing and Sample Size calculation, performing tests and interpreting results.

• Sample size calculation

3.5 Hypothesis Testing with Non-Normal Data

• List of non-parametric tests

3.5.1 Mann-Whitney

• Mann-Whitney test (similar to the 2-sample t-test)

3.5.2 Kruskal-Wallis

• Kruskal-Wallis test (similar to ANOVA)

3.5.3 Mood’s Median

• Mood’s median test

3.5.4 Friedman

• Friedman test (uses the chi-square table for the critical value)

3.5.5 1 Sample Sign

• 1-sample sign test

3.5.6 1 Sample Wilcoxon

• Wilcoxon signed-rank test

3.5.7 One and Two Sample Proportion

• Z test for a single population proportion
• Z test for a comparing two proportions

3.5.8 Chi-Squared (Contingency Tables)
http://math.hws.edu/javamath/ryan/ChiSquare.html
a. Including Tests of Equal Variance, Normality Testing and Sample Size calculation,performing tests and interpreting results.

• http://en.wikipedia.org/wiki/Levene's_test (Levene's test of equal variances)

4.0 Improve Phase
4.1 Simple Linear Regression

• Simple linear regression

4.1.1 Correlation

• Correlation

4.1.2 Regression Equations

• See 4.1
• http://books.google.com/books?id=0yR4KUL4VDkC&pg=PA33&lpg=PA33&dq=extrapolate+beyond+regression+analysis+model&source=bl&ots=p3rqykeXzj&sig=7-YUJ38D_sN1B7sgsC9XqDM387U&hl=en&sa=X&ei=SjXLUbblEMq70QG3pYDICw&ved=0CD4Q6AEwAw#v=onepage&q=extrapolate%20beyond%20regression%20analysis%20model&f=false (Extrapolation beyond a regression model)
• http://people.duke.edu/~rnau/testing.htm (Regression assumptions)
• https://www.google.com/url?sa=t&rct=j&q=&esrc=s&source=web&cd=3&ved=0CDsQFjAC&url=http%3A%2F%2Fwww.southalabama.edu%2Fmathstat%2Fpersonal_pages%2Fnmishra%2FST540%2FHow%2520to%2520interprete%2520the%2520minitab%2520output%2520of%2520a%2520regression%2520analysis.doc&ei=UjHLUeSCBoqw0AGqwIGoDA&usg=AFQjCNGRQHXwQvWCnaxvon4NBGWmptBhVA (Regression output interpretation in Minitab)

4.1.3 Residuals Analysis

• Residual analysis

4.2 Multiple Regression Analysis
4.2.1 Non- Linear Regression

• http://www.statsci.org/smyth/pubs/eoe_nr.pdf

4.2.2 Multiple Linear Regression

• https://www.google.com/url?sa=t&rct=j&q=&esrc=s&source=web&cd=12&cad=rja&ved=0CGoQFjAL&url=http%3A%2F%2Fwww.sjsu.edu%2Ffaculty%2Fgerstman%2Fbiostat-text%2FGerstman_PP15.ppt&ei=meG1UZewEsPh0gGHioCoBg&usg=AFQjCNHL1oAO7922pKSraNQ9r4X0fLzFhw

4.2.3 Confidence & Prediction Intervals

• Multiple regression

4.2.4 Residuals Analysis

• See 4.1.3

4.2.5 Data Transformation, Box Cox

• Making data normal with the Box-Cox power transformation

4.3 Designed Experiments

• http://www.micquality.com/six_sigma_glossary/design_of_experiments.htm

4.3.1 Experiment Objectives

• http://asq.org/quality-progress/2004/03/3.4-per-million/doe-and-six-sigma.html

4.3.2 Experimental Methods

• See 4.3.1
• http://asq.org/learn-about-quality/data-collection-analysis-tools/overview/design-of-experiments-tutorial.html (Main effects and interactions calcutlation)

4.3.3 Experiment Design Considerations

• http://www.weibull.com/hotwire/issue84/hottopics84.htm (screening, optimization and robusteness)

4.4 Full Factorial Experiments
4.4.1 2k Full Factorial Designs

• https://onlinecourses.science.psu.edu/stat503/node/34

4.4.2 Linear & Quadratic Mathematical Models

• http://www.itl.nist.gov/div898/handbook/pri/section1/pri11.htm
• http://www.itl.nist.gov/div898/handbook/pri/section3/pri336.htm

4.4.3 Balanced & Orthogonal Designs

• http://www.micquality.com/six_sigma_glossary/balanced_design.htm (Balanced design) 
• http://support.minitab.com/en-us/minitab/17/topic-library/modeling-statistics/doe/basics/orthogonal-designs/ (Orthogonality)

4.4.4 Fit, Diagnose Model and Center Points

• http://www.itl.nist.gov/div898/handbook/pri/section3/pri337.htm (Center point)

4.5 Fractional Factorial Experiments

• http://www.slideshare.net/tabraham/fractional-factorial-designs

4.5.1 Designs

• See 4.4
• https://onlinecourses.science.psu.edu/stat503/node/57  (Steepest ascent method response surface analysis)

4.5.2 Confounding Effects

• See 4.4

4.5.3 Experimental Resolution

• See 4.4

5.0 Control Phase
5.1 Lean Controls
5.1.1 Control Methods for 5S

• 5S

5.1.2 Kanban

• http://en.wikipedia.org/wiki/Kanban

5.1.3 Poka-Yoke (Mistake Proofing)

• Poka-yoke

5.2 Statistical Process Control (SPC)

• Statistical Process Control Charts: Process Variation Measurement and Management
• http://en.wikipedia.org/wiki/Common_cause_and_special_cause_(statistics) (common cause and special cause variation)

5.2.1 Data Collection for SPC
5.2.2 I-MR Chart

• http://www.statit.com/services/SPCOverview_mfg.pdf
• Control charts

5.2.3 Xbar-R Chart
5.2.4 U Chart
5.2.5 P Chart
5.2.6 NP Chart
5.2.7 X-S chart
5.2.8 CumSum Chart

• http://v5.books.elsevier.com/bookscat/samples/9780750665292/9780750665292.PDF
• Control charts

5.2.9 EWMA Chart

• Control charts
• http://www.itl.nist.gov/div898/handbook/pmc/section3/pmc324.htm

5.2.10 Control Methods
5.2.11 Control Chart Anatomy

• Control charts
• Control charts

5.2.12 Subgroups, Impact of Variation, Frequency of Sampling

• Control charts (Rational subgroups)

5.2.13 Center Line & Control Limit Calculations

• Control charts
• Control charts (Tampering)

5.3 Six Sigma Control Plans
5.3.1 Cost Benefit Analysis

• http://www.dummies.com/how-to/content/performing-a-costbenefit-analysis.html
• http://www.mathsisfun.com/money/net-present-value.html

5.3.2 Elements of the Control Plan

• https://www.moresteam.com/toolbox/control-plan.cfm

5.3.3 Elements of the Response Plan

• http://www.processma.com/resource/spc.php
• http://www.sixsig.info/six-sigma/106.html

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See also: Work in progress (WIP) · Flowchart symbols · Six Sigma symbols · Gemba board · Value stream mapping · Study materials · Statistical distributions · Design of experiments · Process capability · Measurement system analysis · Hypothesis testing · Sample size and sampling · Normality and data transformation · Correlation and regression · ANOVA and non-parametric tests · Attribute MSA (agreement analysis)

Related guides

• ASQ free training guide
• Free Lean Six Sigma training guide
• Basic Lean Six Sigma metrics
• History of Six Sigma and continuous improvement
• Design for Six Sigma (DFSS)
• The DMAIC method

Last updated: November 12, 2026 · Published by Lean Six Sigma Training Guide (sixsigmatrainingfree.com) · How this guide is written