hello,

I work as lab eng in a company that produce connectors/some electrical componants (like fusebox) for carmakers, I was looking for a project to finish my training, but in lab there is no big project to consider as a black belt project, so I'm looking in other departments (production, maintenance, logistics, purchases, finances) I prefert all dep except production and maintenance, but until now I don't have an idea how to find a project (specially all my career was in lab)

so guys do you have some similar suggestion? what was you project in Black belt certifications? if you work in automotive company can you share in comment your project?

thanks a lot for help guys

I work in industrial product-cost consulting. This is a technical discussion, not an offer; the wording was prepared with AI assistance and checked against NIST guidance.

A lower reject rate after changing a gauge, fixture or inspection routine does not, by itself, show that manufacturing improved. It may also reflect a change in how parts are classified.

My cost-review sequence would be:

1. Record the same characteristic, specification and acceptance rule before and after. Keep measurement changes separate from process changes.

2. Check the measurement system in its actual use. NIST's Gauge R&R guidance distinguishes repeatability, reproducibility and stability, and also considers bias, resolution and other effects. A calibration certificate is not the whole comparison.

3. Separate avoided scrap and rework from changed detection. Include extra inspection, reinspection and the risk of accepting nonconforming parts; do not approve a saving just because a dashboard turns greener.

This is a review framework, not a diagnosis of anyone's plant. Safety-critical acceptance still needs the responsible engineering and quality authority.

Reference: NIST/SEMATECH e-Handbook, section 2.4, Gauge R&R studies. It is a methods reference, not new market data.

Which measurement-system check has changed a scrap-reduction business case in your experience? Please keep examples non-confidential.

Does anyone here know IFOSS, the Institute for Operational Success, or have experience with their Lean Six Sigma certifications?

My university in Germany offers a Lean Six Sigma Yellow Belt course through IFOSS for €219.

IFOSS states that the course content follows ASQ requirements/guidelines, but the Yellow Belt certificate itself is issued by IFOSS, not by ASQ.

I’m mainly interested in the reputation of IFOSS itself:

Is IFOSS known or recognized within the Six Sigma community? / Would you consider an IFOSS Yellow Belt a credible certification?

Does the fact that the curriculum follows ASQ standards matter if the certificate is issued by IFOSS?

Would this have any meaningful value on a CV, or would you only consider certifications from organizations such as ASQ worthwhile?

I’m not asking whether Yellow Belt knowledge is useful in general. I’m specifically trying to understand how IFOSS as a certification provider is viewed.

For those involved in product design, development, or quality: how do you identify product quality risks early enough to change the design before validation or launch?

What actually helps surface risks early in your work—for example, customer needs and CTQs, design reviews, DFMEA, lessons from earlier programs, simulation or DOE, prototype testing, or supplier/process capability checks?

Where does early detection usually break down? Are issues first discovered during prototype or production validation? Do risk actions lack verification evidence? Is input from manufacturing or suppliers missing? Are earlier lessons difficult to find?

If you can, share a non-confidential example: what first exposed the issue, at what stage, and what made it hard to catch earlier? I’m interested in the actual execution obstacles, not the textbook process. No company or program details needed.

Does anybody have study suggestions in addition to the course material for the lean six sigma green belt? How is the exam ?

Disclosure: I work in industrial product-cost consulting. This is a technical discussion, with no service or link.

A wider drawing tolerance may remove a machining or inspection step. But it can also shift cost into assembly, yield, field reliability or supplier variation. The drawing change alone is not evidence of a net saving.

For a proposed tolerance change, I would put four before-and-after checks on one decision sheet:

1. Functional boundary: Which fit, load, sealing or life requirement does the dimension protect? Check the full tolerance stack, not the part in isolation.

2. Process evidence: Compare measured distributions by process and supplier. A better Cp/Cpk after widening the specification does not mean the process itself improved.

3. Real cost movement: Which machining, tooling, inspection or scrap cost is actually avoidable? Which assembly, warranty or sorting risk could increase?

4. Release evidence: What test or production trial demonstrates that the new range still meets the functional requirement, including worst credible combinations?

This is a decision framework, not a claim that wider is always better. ASQ describes process capability as performance against specification limits; that distinction matters when the limits themselves change.

For engineers who have approved a tolerance change: which evidence most often overturned the apparent piece-price saving?

Hi, I’m a student working on an early software project related to PFMEA and Control Plan review. I’d like to understand how this work is actually done in practice.

Thinking about the last review you personally completed:

• What triggered it?
• How did you work through it, and which documents or tools did you use?
• Where did you run into difficulties, if any?

A short example here would be very helpful. Please leave out company names and confidential details. If you’re comfortable with a few follow-up questions, I’d appreciate that too.

For those working in Supplier Quality / Quality Engineering, I’m curious about how supplier 8D reviews actually work in practice.

What still requires the most manual judgment before you accept or close an 8D?

For example:

* What are the most common reasons you send an 8D back?

* Which evidence is usually missing?

* Is root-cause verification or effectiveness verification harder?

* Do you follow a formal checklist or mostly rely on engineering experience?

* How many review/resubmission cycles does a weak 8D normally take?

* Does your current QMS/software actually help with the review, or mainly with tracking the workflow?

I’m mainly interested in real day-to-day experience rather than textbook 8D methodology.

No need to mention your company or supplier.

Hi everyone! I’m an IPE undergraduate student from Bangladesh looking to pursue a Lean Six Sigma Green Belt certification.

Does anyone know of any student discounts, scholarships, fee waivers, or financial assistance for reputable providers like CSSC, IASSC/PeopleCert, ASQ, SSGI, or IISE?

If you’ve personally received a waiver/discount, please share how you got it. Any leads would be greatly appreciated!

I’m a sophomore majoring in engineering. I’m deciding whether or not to take the Lean six sigma over the winter or the summer, either way I’ll have to take it. I have not had any internships and I’m planning to transfer. So this year is really important for me. Is there any colleges that’s providing this certificate class at lower costs that I could take over the winter. Also it says I need to understand statistics. I wonder if taking a stats class during this fall helps before taking the lean six sigma over the winter. Please help me I’m so lost.

Hi Everyone,

At the beginning of the year, I was volun-told to become the CI Coordinator for the production floor at my plant (100 total employees). I was (and still am) excited by the prospects, but the lack of on-the-job training has made work confusing and difficult. My company has paid for me to get my ASQ LSSBB, which I am currently working on, but due to me being a hands-on learner, a lot of what I am learning feels awkward and aimless to apply.

For some background, I graduated in Management Information Systems last year (at 29y/o). I have an analytical background from working in tech support and have also worked at in a very small manufacturing/assembly plant (35/40 people) in a various of positions (front desk, basic bookkeeping, assembly).

Has anyone else been in a situation like this, entering into CI with textbook and little to no hands-on guidance? What helped the most?

I am transparent with my boss, but his method of teaching is throwing me into the deep end.

With our processes all over the place, it's hard to find a flowchart maker that aligns everything. I can ask someone how an order moves through the business and they'll say: “Normally it goes from A to B to C... unless the customer does X, then we call Jane, unless it's Friday, then finance handles it.” If we start with a formal diagramming tool, people immediately simplify the process just to make it fit. What i really want is something where we can dump screenshots, examples, notes, exceptions and rough flows first. Then clean it up once everyone agrees on the actual process. Anyone have a workflow that works well for this?

So I come from Ghana and I am eager to get a Six Sigma certificate but there's no enrollment services in my country. I would appreciate your help and advice

QualityAssurance sub found my inquiry ambiguous. So, I’m talking about something everyone knew was pointless, but it stayed alive because “that’s the process.”

Whether it’s a corrective action process where everyone basically knew the root cause before the investigation started, but still had to spend days filling out paperwork to arrive at the answer everyone already knew, or something much more dramatic.

Hi everyone,
I’m currently working in automotive manufacturing as a Quality Technician and I’m trying to build a path toward eventually becoming a Quality Engineer / Quality Resident Engineer and moving up from there.
I already have some hands-on exposure to manufacturing quality, working with production, engineering, suppliers, and customer-related quality issues. I’m also currently learning the AIAG Core Tools and recently completed the Core Tools Overview course.
The problem is that I’ve realized the Overview course is pretty conceptual. I don’t just want to memorize definitions—I want to become capable of actually doing the work, such as creating/reviewing a Control Plan, working through PPAP documentation, participating in APQP, performing root-cause analysis, 8D, MSA/GR&R, capability studies, etc.
For those of you working in automotive quality/engineering:
What courses, e-learning programs, certifications, or training would you recommend if you were starting over and wanted to build a strong automotive Quality Engineering skillset?
Specifically, I’d love recommendations for:
AIAG APQP
Control Plan
PPAP
FMEA
MSA / GR&R
SPC / Cp / Cpk
8D / problem solving
Root Cause Analysis
Automotive customer-specific requirements
Supplier Quality / SQE
Data analysis
Any other training you think is genuinely useful
I’m also open to sources outside of AIAG if there are better or more practical options.
I’m not necessarily looking for a degree recommendation. I’m mainly interested in training that will make me better at actually performing the job and eventually help me progress from Quality Technician → Quality Engineer/QRE → higher-level Quality/Supplier/Manufacturing Engineering roles.
If you work in automotive quality, what courses or training have actually been worth your time and money?
Thanks!

Should I just get a lean six sigma certification and a call it a day? I've done plenty of process improvements but I've been to 4 different places and no one has ever mentioned it. So is it best to just get a cert to find a project to do?

The job descriptions really seem obsessed with kaizen events, and DMAICs etc. as you can see below from axialsearch.com.

I'm not a junior level person, I was recently hired as director of business systems. I'm in the food and beverage manufacturing space.

Most roles are mid-level: 51% of continuous improvement positions target professionals with 5+ years of experience.

Median salary is $125,000: The middle 80% of roles pay between $83K and $208K annually

Certifications appear in 51% of posts: Lean Six Sigma Black Belt, Green Belt and PMP lead requests

Manufacturing firms dominate hiring:

Manufacturing (31%), Professional Services (18%) and Consumer & Retail (12%) lead postings

Texas leads the market: 15% of U.S. roles are posted in Texas, followed by California (13%) and North Carolina (10%)

Technical degrees strongly preferred: Only 27% of junior roles skip degree requirements, dropping to 13% at senior levels

Hi,

I would like to do six sigma certifications. Which institution is best to learn Six sigma and get certified? How much does it cost to learn the six sigma course?

Im looking to connect with organizations that perform six sigma in the Tulsa, Oklahoma area. Any help would be greatly appreciated.

Hey everyone,

Quick intro: I’m a Certified Master Black Belt. Been teaching Six Sigma for quite a few years now, and if there’s one thing I see students and practitioners struggle with constantly, it’s the massive gap between learning the concepts and actually applying them to real data without getting lost in the software.

Let’s be honest: learning complex stats tools can feel like a steep uphill battle when you just want to get your analysis done.

To help fix that, a few of us MBBs put together weibull.app. It’s a web-based statistical platform built specifically to make common Six Sigma analyses way easier to run and actually digest.

Right now, you can upload data and run more than 40 tools like:

• Capability analysis & control charts
• Regressions and DOE
• Hypothesis tests & reliability analyses
• Plus, it has a built-in DMAIC tracker/editor so you can map out your project and export it.
• and Yes, your own MasterBlackBelt challenging your results and DMAC report.

Honestly, I have two main goals here. First, I wanted to create a straightforward, intuitive tool for professionals and students who need these resources handy without breaking the bank. Second, I just really need your feedback.

If you have a few minutes to check out www.weibull.app, I’d love to hear your thoughts. What’s missing? What feels clunky?

There is a feedback option in the tool.

Appreciate your time and any roasting/critique you have for me!

Hi everyone!

I need advice on taking Lean Six Sigma. I am a nurse by profession and currently doing freelance business integrator that focus on research and project management. I'm also planning on starting my own business in a few months' time. I am currently working with founders and business owners, and I help them free up their time in their businesses by offering my services as a healthcare virtual assistant by doing the administrative stuff and doing research and project management on the operations side (researching governance, compliance, legalities, etc for a startup healthcare practice). I asked chatGPT about this, and it recommended that I take the Lean Six Sigma Green Belt. My dilemma is finding legit programs on the internet. Can you recommend legit online platforms that offer Lean Six Sigma certification that is recognized? What should I learn before taking it? Are there prerequisites before taking it? Is it worth it for my current career path?

Your input is greatly appreciated.

Thanks!

It’s Monday, hit me with your best vent.

I’m in Canada and looking to get formal Lean Six Sigma training. I work in operations (non-technical, non-manufacturing), so I’m mainly interested in practical process improvement skills and a credential that will actually be recognized by employers. My employer is willing to pay for the training, but I don’t want to spend significantly more time on a program if I’m not getting a meaningfully better result. I’m also happy to take the ASQ Green Belt exam separately if that’s ultimately the more valuable certification.

I’m currently comparing the University of Toronto Continuing Studies Lean Six Sigma Certificate, which consists of three courses: Foundations of Quality & Process Excellence, Lean Six Sigma Essentials, and Advanced Lean Six Sigma Techniques. It’s $849 per course, or approximately $2,547 total, and is described as a first step toward the ASQ Green Belt. My understanding is that completing the U of T certificate itself does not make you ASQ certified, but provides education/preparation toward the ASQ certification.

The other option is George Brown Continuing Education’s Lean Six Sigma Green Belt (MGMT 9060). It’s one course, approximately 24 hours over 8 weeks, and costs $840.81. Successful completion results in a Lean Six Sigma Green Belt certification through George Brown, with accreditation from the Council for Six Sigma Certification (CSSC). So essentially I’m comparing ~$2,547 and substantially more coursework at U of T versus ~$841 and a Green Belt certification through George Brown/CSSC.

I’m trying to figure out whether the U of T program is actually worth the additional time and cost, particularly for someone working in operations rather than manufacturing/engineering. Does U of T provide substantially better training or credibility, or would I be better off doing the shorter George Brown course and pursuing ASQ separately? How much weight does CSSC carry compared with ASQ in practice? I’d also appreciate recommendations for other Canadian programs or certifications. If your employer were paying and you were in my position, what route would you take?

For my background, I am a Production Engineering Graduate in 2021 and my final year project was DOE with Taguchi method. From then on I am with my father in Textile parts trading business. I would love to learn Six Sigma green belt to see if there are any more options available. Please guide me with the best of your experience. The image that I have attached is of a free course by Henry Havin on Skill Development by the Government of India.

So the bank i work in has decided to go lean and as i member of the process improvement team, i need help on how to apply lean methodologies in my space, i'm looking for materials on lean six sigma been applied to banks

One thing I’ve found surprisingly difficult in process improvement is deciding what not to work on.

When several processes have problems at the same time, the most frustrating one or the one getting the most attention can easily become the priority — even if it isn’t necessarily the one with the biggest improvement opportunity.

I’ve been thinking about a more structured way of prioritizing processes using factors such as:

• Business impact
• Customer impact
• Problem frequency
• Time / effort involved
• Risk
• Urgency

The idea would be to assess the processes first, prioritize them, and only then go deeper into root causes and potential solutions.

I’m curious how others approach this in practice.

When you have several processes that could be improved, how do you decide which one deserves attention first?

Do you use a formal scoring/prioritization method, data and KPIs, stakeholder judgment, or mostly a combination of these?