Lean Six Sigma Workshop

Smart Manufacturing and Lean Systems Research Group


March 26, 2014, 8:00am - 5:00pm


Event Photos Link:Click Here.

Ahad Ali,
Lawrence Tech
Steven Sibrel,
Harman International, and Chair-Elect, ASQ Greater Detroit

Place: Lawrence Technological University, 21000 West Ten Mile Road, Southfield, MI 48075
Room: Marburger Science and Engineering Auditorium (S100, Building #14), http://www.ltu.edu/map/

A training certificate will be provided
Professional Development Equivalent to 0.8 CEU

Registration Fee $50,    FREE FOR VETERANS.
Breakfast and Lunch will be provided.

Register      https://ltu-six-sigma.eventbrite.com/

Payment can be made by check, credit card or purchase order as well. Please contact: aali@ltu.edu.

07:00 Networking Continental Breakfast

Morning Session: 8:00am – 12:00pm

08:00    Quality Leading Indicators (QLIs) as measurable factors of quality performance ahead any changes in quality performance - Javed M Cheema, Aerospace Group, Eaton, Jackson, Michigan

08:40 Lean and Six Sigma Fundamentals - Dr. Ahad Ali, Director, Smart Manufacturing Group, LTU

09:20 Cpk, Cp, Pp, and PpkDr. Jayant Trewn, ASQ Fellow, Lean Six Sigma Master black belt, Performance Coach and Advisor

10:10 Break

10:10 Incorporating the Voice of the Customer in Product and Service Designs to Meet and Exceed Customer Needs and Requirements using QFD and (HOQ): Applications in DFSS, Dr. Amar Sahay, Professor, Operations and Supply Chain Mgt., Salt Lake Comm. College, Salt Lake City, UTAH and Karun Mehta, Senior Research Engineer, QMS Global LLC, Salt Lake City

10:40 Lean Six Sigma Automotive Case Study Judson B. Estes, Master Blackbelt CST, Chrysler Group
11:20 Lean Design® - Driving Lean Efforts into Product Development for Greater Impact, Bill Sprague, Design Prophet®, Munro & Associates, Inc., Troy, MI


12:00 Lunch (Complimentary) at RFOC (Real Food on Campus): All You Can Eat Meal


Afternoon Session: 1:00 pm – 5:00 pm

13:00Structured On-the-Job Assembly Training Methods: Selection of the Media, Methods and Job Aides to Enhance Training Effectiveness and Retention, Dr. Bryan Booker, Eastern Michigan University, Ypsilanti, MI

13:45 Lean and Six Sigma Imprementation Issues, Steven Sibrel, Principal Supplier Quality Engineer, Harman International, Farmington Hills, MI

14:15 Healthcare Delivery Improvement – A Case Study in a Healthcare Facility, Michael Erdman, Quality Process & Strategy Specialist, NAFTA Powertrain Manufacturing, Chrysler Group

15:00 Break

15:15 LSS Case Study - Brian Anderson, Product Development Engineer – Brakes, SANLUIS Rassini, Plymouth, MI

15:45 Lost Secrets of the Original Six Sigma, Gregg Young, President & Founder of Young Associates, Inc., Midland, MI

16:30 Six Sigma Process Capability Analysis When the Process Measurements do not follow a Normal Distribution: Methods, Applications and Computer Analysis - A Case Study, Dr. Amar Sahay, Professor, Operations and Supply Chain Mgt., School of Business and Technology, Salt Lake Comm. College, Salt Lake City, UTAH and Karun Mehta, Sr. Research Engineer, QMS Global LLC, Salt Lake City


Dr. Ahad Ali
Director, Smart Manufacturing and Lean Systems Research Group
Email: aali@ltu.edu; Phone: 248-204-2531


Event Photos: https://picasaweb.google.com/110405055458049659735/LeanSixSigmaWorkshop2014SmartManufacturingGroup


Ahad Ali Ahad Ali, Ph.D.
Assistant Professor and Director of MSIE Program
Director, Smart Manufacturing and Lean Systems Research Group
A. Leon Linton Dept. of Mechanical Engineering
Lawrence Technological University
Southfield, MI 48075, USA

Ahad Ali is an Assistant Professor, and Director of Master of Science in Industrial Engineering in the A. Leon Linton Department of Mechanical Engineering at the Lawrence Technological University, Michigan, USA. He earned B.S. in Mechanical Engineering from Khulna University of Engineering and Technology, Bangladesh, Masters in Systems and Engineering Management from Nanyang Technological University, Singapore and PhD in Industrial Engineering from University of Wisconsin-Milwaukee. He has published journal and conference papers. Dr Ali has done research projects with Chrysler, Ford, DTE Energy, Delphi Automotive System, GE Medical Systems, Harley-Davidson Motor Company, International Truck and Engine Corporation (ITEC), National/Panasonic Electronics, and Rockwell Automation. His research interests include manufacturing, simulation, optimization, reliability, scheduling, manufacturing, and lean. He is member of IIE, INFORMS, SME and IEEE.

Brian AndersonBrian Anderson
Product Development Engineer - Brakes
Plymouth, MI  48170

With a BSE in Mechanical Engineering from the University of Michigan, Brian Anderson started his professional career in automotive braking systems in 2004 and has continued through to the present.  Brian's emphasis during this time has been the engineering of gray cast iron products, specifically brake discs and drums, primarily for the automotive manufacturers headquartered in Southeastern Michigan.  Most notable is Brian's design for a two-piece, dual-material brake disc for which he has two patents pending and has received a presentation award from SAE International in 2011.

While pursuing a Masters of Engineering Management from Lawrence Tech, Brian continues to work and live in Southeastern Michigan with his wife of 10 years, Sara, their 4 year old daughter, Lily, 2 year old son Luke, and soon-to-be-born daughter, Emily.  Personally, Brian and his family enjoy playing games, traditional and electronic, being active in nature, and living out their Christian faith with and through their home church, OakPointe Church, in Novi.

Bryan BookerDr. Bryan Booker

Assistant Professor, School of Engineering Technology
Eastern Michigan University

Dr. Bryan Booker currently serves as an Assistant Professor within the Engineering Management program at Eastern Michigan University.   He invested 24 years serving a variety of engineering and management roles within the Office Furniture and Uranium Enrichment industries.   He has also served as a management consultant with a focus on lean systems applications.  Bryan completed his Doctorate work at Western Michigan University in 2010.  His research is focused on knowledge worker job design, organization design, and lean principles and practices.

Javed M Cheema Javed M Cheema
Aerospace Group, Eaton
Jackson, Michigan

Javed Cheema currently works at Eaton Aerospace. Prior to joining Eaton, Mr. Cheema worked as Director of Quality at Alcoa Howmet Air Power & Propulsion Division; VP of Quality Assurance & LSS at Molex Interconnect and Director of Quality & Lean Enterprise at Benteler Automotive GmbH. Currently, he is also working on his doctoral research, he holds an MS in Industrial & Systems Engineering from University of Michigan, an MBA from University of Central Oklahoma and a Graduate Diploma in Manufacturing Management (Seisan Hoshiki) from Tokyo Poly-Technique University, Japan and declared best International Trainee (Kokusai Kenshuin) in 1994. Mr. Cheema is a Six Sigma Master Black Belt; Master Black Belt DFSS; Certification Chair of Lean Enterprise Division of American Society for Quality, Certified Manager of Quality / Operational Excellence (CMQ/OP), Certified Quality Engineer (CQE), Certified Quality Auditor (CQA) and Certified Engineering Manager (CEM). Mr. Cheema is a Fellow of ASQ, was also awarded joint Fellowship by Japan Productivity Council (JPC) and Japan International Cooperation Agency (JICA).            

Mr. Cheema’s Presentation Synopsis:
Quality Leading Indicators (QLIs) are measurable factors of quality performance ahead any changes in quality performance that start to follow a particular direction or trend. Since these indicators precede other changes, called lagging indicators i.e., cost of nonconformance, escapes, customers’ and suppliers’ returns — it is becoming increasingly important for businesses to identify critical QLIs that can effectively predict future quality performance and proactively mitigate risk. QLIs can be successfully used to forecast forthcoming patterns of overall quality performance.

Michael Erdman
Quality Process & Strategy Specialist, NAFTA Powertrain Manufacturing
Chrysler Group, Auburn Hills, MI

Mike Erdman is currently employed as a Quality Process & Strategy Specialist with Chrysler LLC in the NAFTA Powertrain Manufacturing Division.  His work involves assessing facilities for robust quality process management, coordinating focused improvement initiatives, supporting facilities in developing new ways to achieve their strategic quality manufacturing targets, and problem solving.  He has more than 6 years of experience in areas such as quality, statistical analysis, auditing, primary research, R&D, management, process improvement, and durability testing.  His experiences come from the industrial manufacturing, industrial chemistry, biomedical, and commercial service industries.

Mr. Erdman is currently pursuing a Master of Science in Industrial Engineering with a focus on Quality Systems and a Graduate Certificate in Project Management through Lawrence Technological University.  His research interests include simulation methods, process optimization, scheduling, lean principles, and related techniques for applications in non-traditional and emerging fields.  He received his undergraduate degree in Physics from Oakland University.

Judson EstesJudson Estes
Master Blackbelt and Manager
Chrysler Group
Auburn Hills, MI

Judson Estes is a Master Blackbelt and Manager at Chrysler. He involves in building organizations to focus on data driven decisions in the fields of innovation, robust design and quality production. His specialties are in design for six sigma, lean, six sigma, shainin, kepner tregoe, problem solving, simulation, modeling, testing, and weibull, Estes has 27 years automotive industry experience with problem solving for chassis, and interior, body sections of vehicle manufacturing. He was engineering manager at Daimler - Mercedes Benz Cars and Trucks with shainin master, six sigma, critical thinking coach and kepner tregoe program leader. Estes is a pioneering leader that is capable of implementing significant and lasting change to a large organization. He received Shainin Top 5 Manager of the Year 2007. Estes has Bachelor of Science in Physics from Wayne State University.

Robert Ptacek Robert Ptacek
President and CEO, Competitive Edge Training & Consulting
Partner, Global Lean Institute
Grand Rapids, Michigan 49504

Mr. Ptacek is a Partner in Global Lean Institute, and President and CEO of Competitive Edge Training and Consulting, a firm specializing in leader and organizational development, and Lean Enterprise transformations. He is an Approved Scanlon Leadership Network Consultant and a Senior Advisor to the National Association for Job Shops and Small Manufactures (NAJS). Mr. Ptacek holds a BS in Metallurgical Engineering from Michigan Technological University, Houghton, MI (USA), and Masters of Management from Aquinas College, Grand Rapids, MI (USA).

Mr. Ptacek is an adjunct instructor of Management Principles, Manufacturing Strategy, and Total Quality Management, and has instructed at Grand Valley State University, Aquinas College, Davenport University, and currently instructs in the Lean Champion Certification program at Grand Rapids Community College. Mr. Ptacek has an extensive client list and has provided Lean and Leadership training and consulting in North America, Asia, and Europe.

Mr. Ptacek has authored several articles on principled Leadership and continuous improvement topics. He is the author and illustrator of Shop Suey comics for industry, a comic book formatted training publication, the Supervisor Pocket Guide, and the Lean Sim Machine™ Advanced Lean Training Manual, and is on the advisory board for the Lean Pocket Guide and related materials offered by MCS Media.

Mr. Ptacek has held leadership positions in Quality, Sales, and Operations Management, and has over 25 years of practical experience implementing continuous improvements in a variety of industries. He speaks on leadership and continuous improvement topics for several industry associations including, Precision Metal Forming Association (PMA), Society of Manufacturing Engineering (SME), American Society for Quality (ASQ), American Mold Builders Association (AMBA), National Association for Job Shops and Small Manufactures (NAJS), and the Scanlon Leadership Network (SLN).

Dr. Amar Sahay
Professor, Operations and Supply Chain Management
School of Business and Technology
Salt Lake Community College
Salt Lake City, Utah

Dr. Amar Sahay is engaged in teaching, research, consulting, and training for the past 17 years in various Utah institutions. He has taught/teaching at several institutions including the University of Utah, Salt Lake Community College, Weber State University, and the Westminster College. At present, he teaches and consults in the areas of Supply Chain Management, Lean Six Sigma Quality, Manufacturing Engineering/Technology, Quantitative Methods, and Computer Applications in Quality, Six Sigma in service and manufacturing. By profession he is an engineer and a professor. He is the founder of QMS Global LLC; a company engaged in research, training, consulting, and providing software solutions in the areas of lean six sigma quality, manufacturing, and services. Amar has a B.S. in Production Engineering (Birla Institute of Technology, India), M.S. in Industrial Engineering and Ph.D. in Mechanical Engineering (both from University of Utah, Salt Lake City, Utah, USA). His Ph.D. emphasis is on Computer-aided Design and Manufacturing (CAD/CAM), Manufacturing/Quality Engineering, and Production Systems. He is a certified Six Sigma Master Black Belt.

Amar is a senior member of Institute of Industrial Engineers, senior member of American Society for Quality (ASQ), a member of Alpha-pi mu, the national Industrial Engineering honor society. He was a senior member of Society of Manufacturing Engineers. He also served in the editorial board of the International Journal of Industrial Engineering: Theory, Application, and Practice for four years. He was also a member of AEA, the American Evaluation Association. Amar has contributed approximately 35 articles in national and international journals, co-authored and authored books, and presented several papers in national and international conferences. He is the author of Six Sigma Quality: Concepts and Cases_Volumes I and II and Statistics and Data Analysis Concepts for Business. In addition, he has written comprehensive training manuals for each of the DMAIC phase of Six Sigma.

He has published/presented more than 12 papers in Lean, Six Sigma and Design for Six Sigma. The details of his work relating to Six Sigma Quality/Statistics and Data Analysis are available on the website: http://www.realleansixsigmaquality.com/lss/index.html. Amar has worked on several funded research projects including the Air Force and IBM funded projects on computer-aided manufacturing and quality. He has extensive research, teaching, and consulting experience in areas of computer-aided manufacturing, Quality and Process Control, Operations and Supply Chain Management, Lean Six Sigma, statistical methods, and design and analysis of manufacturing systems. His international experience includes India and China.

Steven Sibrel

Steven Sibrel
Principal Supplier Quality Engineer
Harman International
Farmington Hills, MI

Steve Sibrel is a business process improvement trainer, coach and auditor with over 35 years of experience in the business and manufacturing world. He is currently working as Principal Supplier Quality Engineer at Harman International, a manufacturer of audio and infotainment systems for consumer, professional, and automotive industries, with well known brands such as JBL, Lexicon, Crown, Infinity, Mark Levinson, Becker and Harman-Kardon. Previously he held a number of engineering and management positions in diverse industries at Applied Materials (Semiconductor), NEC (Telecommunications) and Texas Instruments (Military). He has conducted over 200 supplier audits in North America, Europe, and Asia and is a Lead Auditor for ISO/TS16949, ISO9001, ISO13485, ISO17025, and 21CFR820. 

He has been the Chair for Professional Development for the ASQ Detroit section since 2008. He received the Distinguished Service Award in 2008 and the Leadership Award in 2013 from ASQ.  Current ASQ Certifications held are Six Sigma Black Belt, Quality Engineer, Quality Inspector, Quality Auditor, and Manager of Quality/ Organizational Excellence. He is an adjunct facility member at Macomb Community College. Steve has a BSEE degree from Rose Hulman Institute of Technology and an MSEE degree from Southern Methodist University.

Bill Sprague Bill Sprague
Design ProphetTM
Munro & Associates, Inc.
Troy, MI

Bill Sprague is a Design Prophet® for Munro & Associates, Inc.  Mr. Sprague works to extend the concepts of Design For Assembly (DFA)  into Lean Design® for a variety of products including automotive, medical devices, defense, computers, office furniture, and others.  This work combines training with hands-on application to deliver immediate savings on team

projects.  Dramatic savings prior to product release cover both cost and quality improvements including elimination of non-value added step requirements, poka yoke issues, ergonomic problems, and overall product complexity to simplify production. He was an early industry pioneer in Design For Manufacturability implementation at NCR Corporation with project leadership on retail terminal and checkout scanner projects using DFA, cross-functional teams, and advanced CAD/CAM tools.  Later operating at the corporate level, he drove DFM efforts to provide competitively superior products, faster to market which were benchmarked as industry leading.  He also led multi-plant software selection projects for MRP, PDM, and MCAD tools.

Recognition as an implementation leader in Product Development improvements, he has spoken at over 100 industry, specific company, and internal employer conferences worldwide.  He has published six papers on related topics including DFA/Concurrent Engineering Case Studies, Concurrent Engineering and DFA Implementation, Design For Environment, and Culture Change aspects for DFA.  His work and views on industry trends have been cited in numerous publications including Business Week, Design News, Industry Week, and others. His expertise in overall Product Development improvement techniques and tools has been recognized with numerous awards including the Assembly Production Achievement thru Technology (PAT) Award, a nomination for the U.S. President’s National Medal of Technology, the NCR Corporate Manufacturing Award, and twelve NCR Technology Author Awards.  He earned his B.S. in Industrial Engineering from Purdue University and his Masters in Business Administration from Florida Atlantic University.   He is a member of IIE and SAE.

Jayant Trewn, ASQ Fellow, Ph.D. Jayant Trewn, ASQ Fellow, Ph.D.
Lean Six Sigma Master black belt
Performance Coach and Advisor

Jayant Trewn is an Industrial Engineer specializing in Quality Systems design, development, implementation and management.   Jayant has accumulated over a decade of experience working in healthcare organizations such as Spectrum Health Medical Group, Beaumont Hospitals, and service organizations such as Thomson Reuters and Lason Systems, where he built healthcare and service delivery process improvement programs based on lean, Six Sigma and PDCA concepts.  He also worked for two years at Thomson Reuters working as Director of Quality Assurance, IP and Science division, managing the quality of acquisition of data for scientific research.

Jayant has been teaching quality engineering since 1997 in his roles as Adjunct Professor at Lawrence Technological University, Wayne State University and Oakland University, all in Michigan, in addition to giving quality engineering talks, seminars and workshops at numerous national and international conferences.  Jayant has also served as a Research Analyst for Wayne State University, Center for Urban Studies and Office of Strategic Planning from 1993 to 1999.

Jayant has written two books, Practical Lean Sigma for Healthcare and Multivariate Statistical Methods in Quality Engineering and he has been published in international journals.  Jayant is a Fellow of ASQ and he holds a Doctorate degree in Industrial Engineering from the College of Engineering, Wayne State University, Detroit, MI, USA. He earned his MBA in Information Systems at Wayne State University and his Bachelor of Engineering degree from Madras University, India.  Connect with Jayant at LinkedIn

Gregg Young Gregg Young
President and Founder
Young Associates, Inc.
Midland, MI

Gregg Young is President and Founder of Young Associates, Inc. (http://youngassocinc.com) He has worked with large corporations and small businesses helping them to solve problems, improve quality, increase profits, and develop successful new products. Gregg has spent over 40 years solving problems, leading teams, and teaching problem solving skills. He experienced both successes and frustrations, so he studied dozens of processes searching for best practices he could add to his clients’ processes so they would deliver bigger results faster. When he discovered that best practices do exist, it sparked his passion to share this knowledge, so that anyone can solve problems as effectively as Sherlock Holmes solved crimes. He is the author of three books focused on upgrading business processes by adding convergent, observation-based methods to existing processes. His latest book is Reasoning Backward: How Sherlock Holmes Can Make You a Better Problem Solver. It adapts these techniques for students as well as businesses, providing everyone with the skills they need to solve problems effectively and create a competitive advantage in the global marketplace. His most recent work has been the development of Active Time Profiles, a graphic tool to accelerate and focus cycle time reduction in any system. Young has a B.A. in Chemistry from Rice University. You can email him at gregg@youngassocinc.com.

ASQ Greater Detroit Section
SME Student Chapter - LTU
IEOM Student Chapter - LTU