• Lean Six Sigma Green Belt - Manufacturing

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


 

Course Topics

 
Time Commitment and Work Pace

Estimated: 60 self-paced hours

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

All requirements must be completed within 180 days after your start date. This is a self-paced online course consisting of 24 lecture modules with 22 exercises (multiple choice tests to complete after each learning module). Most lecture tapes are approximately one hour in length. While the course is self-paced, we recommend completing two sessions/week.

Module Topics

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

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

Participants pursuing their University of Michigan Lean Six Sigma Green Belt Certification are required to:

  • Complete all required online lecture modules
  • Complete all testing exercises with an overall cumulative score > 80%
  • Successfully complete Green Belt Project (reviewed by U-M faculty)

Upon successful completion, you will be mailed your University of Michigan Lean Six Sigma Green Belt Certification.

Prerequisites

A basic understanding of statistical analysis methods is recommended, including:

  • Basic Microsoft Excel Skills (e.g., perform calculations, manipulate data, create graphs)
  • Basic Statistics (e.g., Descriptive Statistics such as median, median, standard deviation, Frequency Analysis/Histogram, Normal Distribution, Simple Linear Regression)
CEUs

Upon successful completion of this 40-hour program, students will receive four Continuing Education Units (CEUs). This course is not for academic credit. CEU credits may not be applied toward a degree. The University of Michigan will provide necessary documentation upon request.

Project Information

Lean Six Sigma DMAIC analysis may be applied to a vast array of process improvement opportunities. Participants are expected to complete a project to practice and apply course concepts.

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Course Access & Technical Requirements

All lecture notes, homework sets, solutions, and tutorials are available through the course’s online learning management system.

Technical Requirements

Support

Administrative/Online Technical Support

Support staff are available via phone and email to help with administrative and technical issues during our normal business hours (Monday through Friday 8:00 a.m. to 5:00 p.m. Eastern Time). 

Content Questions/Certification Project Support

Candidates are welcome to contact the course instructors for content questions and project support. The instructors will provide support via e-mail, phone consultation, and/or online videoconferencing.

Program Faculty

 
 
Patrick Hammett
Patrick Hammett
Director of Academic Programs and Learning Systems, Integrative Systems + Design
Lead Faculty, Six Sigma Programs
Lecturer, Integrative Systems + Design
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Don Lynch
Don Lynch
Instructor, Integrative Systems + Design
VP of Operations, Battery Solutions
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Luis Guzman
Luis Guzman
Lecturer, Industrial & Operations Engineering
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