PR8071 Lean Six Sigma Syllabus:
PR8071 Lean Six Sigma Syllabus – Anna University Regulation 2017
Objective:
• To gain insights about the importance of lean manufacturing and six sigma practices.
Unit I Lean & Six Sigma Background And Fundamentals
Historical Overview – Definition of quality – What is six sigma -TQM and Six sigma – lean manufacturing and six sigma- six sigma and process tolerance – Six sigma and cultural changes – six sigma capability – six sigma need assessments – implications of quality levels, Cost of Poor Quality (COPQ), Cost of Doing Nothing – assessment questions
Unit II The Scope Of Tools And Techniques
Tools for definition – IPO diagram, SIPOC diagram, Flow diagram, CTQ Tree, Project Charter – Tools for measurement – Check sheets, Histograms, Run Charts, Scatter Diagrams, Cause and effect diagram, Pareto charts, Control charts, Flow process charts, Process Capability Measurement, Tools for analysis – Process Mapping, Regression analysis, RU/CS analysis, SWOT, PESTLE, Five Whys, interrelationship diagram, overall equipment effectiveness, TRIZ innovative problem solving – Tools for improvement – Affinity diagram, Normal group technique, SMED, 5S, mistake proofing, Value stream Mapping, forced field analysis – Tools for control – Gantt chart, Activity network diagram, Radar chart, PDCA cycle, Milestone tracker diagram, Earned value management.
Unit III Six Sigma Methodologies
Design for Six Sigma (DFSS), Design for Six Sigma Method – Failure Mode Effect Analysis (FMEA), FMEA process – Risk Priority Number (RPN)- Six Sigma and Leadership, committed leadership – Change Acceleration Process (CAP)- Developing communication plan – Stakeholder.
Unit IV Six Sigma Implementation And Challenges
Tools for implementation – Supplier Input Process Output Customer (SIPOC) – Quality Function Deployment or House of Quality (QFD) – alternative approach –implementation – leadership training, close communication system, project selection – project management and team – champion training – customer quality index – challenges – program failure, CPQ vs six sigma, structure the deployment of six sigma – cultural challenge – customer/internal metrics.
Unit V Evaluation And Continuous Improvement Methods
Evaluation strategy – the economics of six sigma quality, Return on six Sigma (ROSS), ROI , poor project estimates – continuous improvement – lean manufacturing – value, customer focus, Perfection, focus on waste, overproduction – waiting, inventory in process (IIP), processing waste, transportation, motion, making defective products, underutilizing people – Kaizen – 5S.
REFERENCES:
1. Forrest W. Breyfogle, III, James M. Cupello, Becki Meadows, Managing Six Sigma: A Practical
2. Fred Soleimannejed, Six Sigma, Basic Steps and Implementation, Author House, 2004 Guide to Understanding, Assessing, and Implementing the Strategy That Yields Bottom-Line Success, John Wiley & Sons, 2000.
3. James P. Womack, Daniel T. Jones, Lean Thinking, Free Press Business, 2003
4. Michael L. George, David Rownalds, Bill Kastle, what is Lean Six Sigma, McGraw – Hill 2003
5. Thomas Pyzdek, The Six Sigma Handbook, McGraw-Hill, 2000.