Six Sigma Green Belt, Design for Six Sigma, DMAIC Six Sigma

Design for Six Sigma Green Belt Level 1 | Online

  • Take Process Improvement to the Next Level

    Cost Delivery Options
    Includes QETools Software®

    Design for Six Sigma (DFSS) is an evolving advanced practice that can be applied to all kinds of products, services, and system designs to take process improvement to the next level. It is estimated that 70-80% of quality problems originate in product definition and design. One of the main themes of Design for Six Sigma (DFSS) is to move from reactive to predictive by designing quality into the product, instead of waiting until production starts and then finding and attempting to fix issues. In addition, DFSS can be an enabler for new product development.

    Working in new product development is an exciting and enriching career, but also challenging. The Green Belt course is focused on improving your skills to succeed in this critical area. It examines key concepts and introduces proven tools to effectively translate customer requirements into functional requirements and then ultimately into more robust product, service, and process designs.

    As many organizations improve their operational quality, they recognize the need to focus their quality improvement efforts on designing quality into their products and services. This Green Belt course, organized around the IDDOV Design for Six Sigma Methodology, examines methods and analysis tools for designing in quality to increase customer satisfaction and reduce downstream manufacturing quality and warranty concerns.

    The IDDOV methodology involves identifying customer requirements, evaluating design concepts, and then optimizing new processes to meet the customer-driven design objectives. The tools and methods covered include Voice of the Customer Analysis, Balanced Design Scorecards, Transfer Functions, Failure Mode and Effects Analysis, TRIZ, Pugh Method, Hypothesis Testing, Tolerance Simulation and Analysis, and Product/Process Validation.

    The Green Belt Level I course focuses on the core concepts and methods of applying the IDDOV methodology within the new product development process. In this course, all of the tools and analysis techniques covered use Microsoft Excel and Add-In templates that are included with the course.

  • Components

    This course involves viewing lecture modules, participating in student discussion boards, completing homework exercises, and case studies. The Green Belt Level I course is comprised of 24 modules which are detailed below. It involves 40-50 hours of material which students should be able to complete within 180 days or less.

    1. Course Introduction—New Product Development Challenges
    2. IDDOV Methodology/ Identifying Projects
    3. Defining Customer Requirements: Voice of the Customer
    4. Survey Analysis Methods
    5. Developing Functional Requirements/FAST Diagrams
    6. House of Quality
    7. Benchmarking
    8. Design Concept Generation
    9. Creativity and Innovation Tools
    10. TRIZ Overview
    11. Design Concept Selection: Design Scorecards, Pugh Matrix
    12. Design Failure Mode and Effects Analysis (DFMEA)
    13. Design Issue Countermeasures, DFX Analysis, Axiomatic Design
    14. Design Optimization: Transfer Functions, P-Diagrams, and Robustness
    15. Two Group Hypothesis Tests (t-test, F-test, 2 Proportion Tests)
    16. One Way ANOVA Tests
    17. Two Way ANOVA Tests
    18. Problem Solving Session: Hypothesis Tests
    19. Tolerance Analysis: Statistical Tolerance Methods
    20. Tolerance Simulation: Development and Allocation
    21. Problem Solving Session: Tolerance Simulation
    22. Product Design Verification and Validation
    23. Process Validation
    24. Course Summary
    • Program Details


    Green Belt Level I participants should possess a basic understanding of statistical analysis methods (e.g., Six Sigma Green Belt or equivalent) and basic Microsoft Excel skills.

    Who Should Take This Course

    The Design for Six Sigma Green Belt Level I course is aimed primarily at Product Designers, Manufacturing Engineers, and Project Managers working in new product development.


    Design for Six Sigma Green Belt Level I Certification requires the following:

    • Completion of all online testing exercises with a score of 80% or higher
    • Completion of a project using the Identify-Define-Design (IDD) Six Sigma Methodology. They then must conduct an IDD analysis to translate voice of the customer requirements into a new design concept using Design for Six Sigma tools and methods covered in the course. 
      • Participants should select a project from their workplace. If unable to find a work project, participants may use a University of Michigan Green Belt Case Study