Roger Ellis


iSixSigma Membership


Roger Ellis


Six Sigma Master Black Belt


Business Experience

I am a self-employed educator, trainer and consultant specializing in the fields of lean manufacturing, project management, Six Sigma, business process analysis, throughput improvement, design for assembly and manufacturing, operations management, industrial engineering, and production and inventory control.

Since becoming self-employed in 1998 I have served as an instructor for the University of Phoenix, teaching undergraduate and graduate business courses and Corporate Education Department certificate courses in business and management. I am a seminar leader and course developer and have performed work for the Corporate Education Department at Arizona State University, the American Management Association, the Institute of Industrial Engineers, the Six Sigma Academy, Florida Atlantic University and Key Performance LLC as well as numerous private clients. I am certified as a Project Management Professional (PMP) by the Project Management Institute and as a Six Sigma Master Black Belt by Six Sigma Partnering LLC. I consult internationally with my own clients as well as performing contract work for other consulting and training companies. I serve on the advisory board for Emergency Excellence, an emergency medical department consulting organization.

I retired from General Motors on March 1, 1998 after a thirty-year career in manufacturing and manufacturing engineering. I was hired as a cooperative education student at General Motors Institute (GMI) and employed by General Motors at the Chevrolet Tonawanda NY Forge Plant in the fall of 1967, where I worked an engineering student, Inspection Foreman and Quality Control Engineer through 1976.

In 1977 I transferred to Chevrolet Central Office in Warren MI and assumed increasing responsibilities in material control system development and implementation, and manufacturing business planning for Chevrolet Manufacturing. I spent two years of this time implementing material control systems for a new GM engine plant in Ramos Arizpe, Mexico (along with learning to speak conversational Spanish).

In 1985, I joined the newly created Chevrolet-Pontiac-Canada group of GM in the industrial engineering department where I was responsible for engine capacity planning and investment analysis. I was next promoted to Industrial Engineering Platform Manager for two of the CPC car programs, and was responsible for design for assembly and manufacturing as well as all industrial engineering activities. I assumed the position of Manager of the Vehicle Launch Center Corporate Industrial Engineering activities for GM North American Operations in 1992.

In 1996 I transferred to the GM Fairfax Assembly Plant in Kansas City KS. I participated in the launch of the 1997 Pontiac Grand Prix and the 1998 Oldsmobile Intrigue automobiles by supervising the industrial engineering groups for the paint and body manufacturing departments. I then implemented the Quality Verification (ANDON) system and various error-proofing applications in the chassis department as a member of the Competitive Manufacturing Department until my retirement from General Motors effective March 1, 1998

Teaching Experience

I have extensive industrial teaching experience, especially in the areas of lean manufacturing concepts and application, Six Sigma Yellow, Green, Black and Master Black Belt certification, design for assembly and manufacturing, business process analysis, project management, and production scheduling and inventory control.

During my time in Kansas City, I taught Operations Management in The Master of Business Administration degree program at Webster University. Webster is a part-time, adult oriented school that emphasizes the use of adjunct faculty who are practitioners in their field. I was approved to teach more than twenty courses for the University of Phoenix at both the undergraduate and graduate level, primarily in Management, Project Management, and Production and Inventory Management. I began teaching for UOP in 1998, and have taught in the classroom as well as online in an Internet-based degree program for several years.

I have developed and conducted seminars in lean manufacturing for the Corporate Education Department of Arizona State University in Tempe AZ. These seminars provided continuing engineering education for corporate clients of the University. I developed and conducted seminars for the American Management Association in Effective Production, Operations and Plant Management; Production and Inventory Control; Business Process Improvement; Project Management; and Lean Manufacturing. I developed and conducted Introduction to Lean Manufacturing and Project Management seminars for the Institute of Industrial Engineers. I developed a four-week Lean Manufacturing Expert Training program for the Six Sigma Academy of Scottsdale AZ. I am currently developing and teaching Project Management and Six Sigma training programs for Key Performance in partnership with Florida Atlantic University in Boca Raton, FL. These programs are delivered both in the classroom and online using BlackBoard course delivery software. Since 1998 I have facilitated seminars that attracted participants from more than 1,000 companies, earning superior evaluations.

I teach for two primary reasons. First, teaching challenges me to continuously improve my base of knowledge and my skills in transferring that knowledge to others. Second, I enjoy the interaction with my students and find that I learn much from them.

Consulting Experience

I have performed assessments of the state of implementation of lean manufacturing, Kaizen workshops, in-depth lean manufacturing training and have spearheaded company-wide lean implementation efforts for numerous manufacturing clients.


I graduated from Technical Memorial High School in Erie PA in 1967 with a Trade Certificate in Drafting.

I was accepted as a cooperative engineering student at General Motors Institute (GMI) in the fall of 1967. I graduated from GMI in 1972 with a Bachelor of Science in Industrial Engineering. GMI is now known as Kettering University and is located in Flint MI.

Immediately upon graduation from GMI, I entered the Master of Business Administration program at the State University of New York at Buffalo and earned the MBA degree in 1976.

I began studies for a Master of Science in Engineering from Purdue University through the GM Technical Education distance-learning program in 1988. The degree was earned in 1994, with concentration in Industrial Engineering.

Professional Certifications

Project Management Professional (PMP) Project Management Institute
Six Sigma Master Black Belt Six Sigma Partnering LLC


I am a licensed private pilot (airplane single engine land) and hold an instrument rating. I enjoy photography and have done extensive work for publication. I have been continuously involved with the drum and bugle corps activity since 1966 as a marching member, corps officer, circuit publicist, show chairman, writer and photographer, and most of all a fan.

My wife Mitzi and I live full time in Scottsdale, Arizona. We enjoy New York Yankees baseball and travel by cruise ship. We also teach beginning and intermediate ballroom dancing. We are owned by a Cairn terrier named M.C.

Certification Level

Six Sigma Master Black Belt

Certification Body

Six Sigma Partnering LLC

Certification Year


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