Objective
Six Sigma is a structured methodology for solving problems with tools that can be applied to the problem-solving process. Although initially used to improve quality, Six Sigma is now used by many companies to make cost-saving improvements. Lean system aims at minimizing the cost of any process by eliminating various types of waste in manufacturing and services. Lean principles are merged with or are embedded within the Six Sigma principles. Participants of the course will learn to integrate these two concepts to both deliver faster results and achieve the best competitive position by concentrating on the use of tools that will have the highest impact on the already established performance levels.
Contents
(I) -Introduction to Six Sigma, TQM vs Six Sigma, Average and Variation, Six Sigma as a Statistic, Six Sigma as a Management Philosophy, Process Capability Index
-Lean Concepts, Lean Six Sigma
-Six Sigma Methodology, DMAIC, Role of Management in implementation of Six Sigma
-Case Discussion
(II) Qualitative Six Sigma Tools:
Quality Function Deployment (QFD)
Failure Modes and Effects Analysis (FMEA) and Fault Tree analysis (FTA)
Fishbone Diagram
Process Flow Diagram
Qualitative Correlation Test
Case Discussion and Problem-Solving
(III) Foundations for using Statistical Six Sigma Tools:
Getting good samples & data
Random vs. Assignable Causes: Use of probability in detecting assignable causes
Data Plots and Distribution
(IV) Statistical Six Sigma Tools:
Testing for Statistically Significant Change in the Process using variables data: (i) sample vs. population, (ii) between two samples, Case Discussion & Problem-Solving
Testing for Statistically Significant Change in the Process using proportional data: (i) sample vs. population, (ii) between two samples, Case Discussion & Problem-Solving
Testing for Statistically Significant difference in two or more number of processes/treatments using ANOVA and ANOM, Problem-Solving
Testing for Statistically Significant Change with Non-Normal Distribution Processes, Case Discussion and Problem-Solving
(V) Other Six Sigma Tools:
Design of Experiment (DOE) and Orthogonal Array
Advanced Control Charts and Acceptance Sampling
Taguchi Methods for Robust Design, Reliability Analysis & Prediction
(VI) Sessions by Practitioner
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Evaluation:
(iii) END-TERM EXAMINATION: 30%
(iv) GROUP TASKS and Class Participation: 15% (Group Presentation/Group Case Analysis/ Group Problem Solving and response in the class )
(iv) PROJECT: 15%