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The College of Engineering: Integrative Systems + Design

Manufacturing — Lean six Sigma Green Belt

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Description

Earn Your Green Belt Online from the University of Michigan

Learn how to effectively solve problems by integrating Lean and Six Sigma within the DMAIC approach.

This course will set you up with a structure to systematically frame problems, collect data productively, and implement sustainable solutions. After completing the program—including an improvement project at your organization—you'll earn a University of Michigan Lean Six Sigma Green Belt certification.

Manufacturing Track

Using examples and case studies, this course focuses on applications primarily drawn from manufacturing companies. Project results include increased throughput, improved equipment utilization, reduced maintenance costs, and more.

Demonstrate your ability to conduct thorough problem-solving analysis toward achieving measurable results with a University of Michigan Lean Six Sigma Green Belt certification.

Learning Objectives

Understand variability through the graphical representation of data

Describe a process visually through process mapping techniques

Apply DMAIC problem solving process toward process improvement at the Green Belt level

Interpret test results and draw conclusions based on data

Develop recommendations and control plans to improve processes

Complete a process improvement project outside of class that demonstrates the application of the full DMAIC methodology

Green Belt Program Overview

Time Commitment and Work Pace

Estimated: 60 self-paced hours

  • 40 hours (approximately) for lecture recordings and exercises
  • 10-30 hours for project work

Module Topics

The following modules are required, and you will also receive access to optional supplemental material.

  • Continuous Improvement Overview – Integrating Lean and Six Sigma, Classic Forms of Waste, Kaizen
  • DMAIC Problem Solving Process
  • DEFINE: Requirements Flow Down, Linking Customers to Business Performance Metrics (VOC/VOB), Project Charters
  • Process Maps: SIPOC, Swimlane, Process Mapping Diagram
  • MEASURE: Exploring Data Patterns & Distributions (Run Charts, Histograms, Box Plots), Outliers (Supplement: Course Software Tutorial)
  • Descriptive Statistics (Sampling, Mean, Median, Variation)
  • Measuring Current State Capability (Yield, PPM Defective, DPMO)
  • Rolled Yield Analysis (Types of Yield, Rolled Yield, Normalized Yield)
  • Process Stability - Overview of Statistical Process Control (Variable and Attribute Control Charts)
  • Measurement Systems Analysis (MSA)
  • Value Stream Mapping – Part 1 (Current State Map, Value Add Timeline)
  • Value Stream Mapping – Part 2 (Value Stream Productivity Analysis, Effective Process Time, Lean Levers: Pitch Interval, Volume/Mix Leveling, and Future State Maps)
  • ANALYZE: Qualitative Analysis (Affinity, P-Diagram, Cause-Effect Diagram, 5 Whys)
  • Stratification Analysis (Grouping Variables, Multiple Box Plots)
  • Check Sheets and Pareto Analysis
  • Two Group Hypothesis Tests (F-tests, t-tests, 2 proportion tests)
  • Two-Variable Analysis: Scatter Plot/Linear Regression/Correlation
  • Hypothesis Test: One Factor ANOVA
  • IMPROVE: 5S Process, Standardized Work, Training, Error Proofing, Visual Aids, Process Monitoring
  • Flow Improvements (Push vs. Pull Systems, Little's Law, Batch Size Reduction, Layout Improvement)
  • Failure Mode and Effects (FMEA) Analysis
  • CONTROL: Methods of Control
  • Project Selection and Scoping
  • Applying the Six Sigma Methodology and Course Summary

Experts

Dr. Patrick Hammett is the Lead Faculty for the University of Michigan College of Engineering's Six Sigma Programs and teaches related Quality and Statistical Analysis Method courses as a Lecturer for the Integrative Systems +Design Department. As lead instructor for live and online Six Sigma tra...
Dr. Guzman is lead faculty in the University of Michigan College of Engineering in Industrial and Operations Engineering (IOE) and the Division of Integrative Systems + Design (ISD), where he has taught several courses since 2003. His teaching and research is focused on the application of data a...
Donald P. Lynch, Ph.D. received his B.S. in Mechanical Engineering from Michigan Technological University, MBA from Eastern Michigan University, Ph.D. in Mechanical (Industrial) Engineering from Colorado State University, and a post Graduate Certificate in Lean Six Sigma from the University of Mi...
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