IL4075 Lean Manufacturing and Six Sigma Syllabus:
IL4075 Lean Manufacturing and Six Sigma Syllabus – Anna University PG Syllabus Regulation 2021
OBJECTIVES:
Summarize the basics of Lean and Six Sigma.
Describe the need and the process of integrating Lean and Six sigma.
Identify and select the resources required for LSS Projects and selection of projects including Team building.
Infer the DMAIC process and study the various tools for undertaking LSS projects.
Relate how to institutionalize the LSS efforts.
UNIT I INTRODUCTION TO LEAN AND SIX SIGMA
Introduction to Lean- Definition, Purpose, Features of Lean ; Top seven wastes, Need for Lean management, The philosophy of lean management, Creating a lean enterprise, Elements of Lean, Lean principles, the lean metric, Hidden time traps. Introduction to quality, Definition of six sigma, origin of six sigma, Six sigma concept and Critical success factors for six sigma; Case analysis.
UNIT II INTEGRATION OF LEAN AND SIX SIGMA
Evolution of lean six sigma, the synergy of Lean and six sigma, Definition of lean six sigma, the principles of lean six sigma, Scope for lean six sigma, Features of lean six sigma. The laws of lean six sigma, Key elements of LSS, the LSS model and the benefits of lean six sigma. Initiation – Top management commitment – Infrastructure and deployment planning, Process focus, organizational structures, Measures – Rewards and recognition, Infrastructure tools, structure of transforming event and Launch preparation; Case study presentations.
UNIT III PROJECT SELECTION AND TEAM BUILDING
Resource and project selection, Selection of Champions, Identification of potential projects, top down (Balanced score card) and Bottom up approach – Methods of selecting projects – Benefit/Effort graph, Process mapping, value stream mapping, Predicting and improving team performance, Nine team roles and Team leadership; Case study presentations .Black belts, Training of Black belts
UNIT IV THE DMAIC PROCESS AND TOOLS
The DMAIC process – Toll gate reviews; The DMAIC tools; Define tools – Project definition form, SIPOC diagram; Measure tools – Process mapping, Lead time/cycle time, Pareto chart, Cause and Effect matrix, FMEA; Idea – generating and organizing tools – Brainstorming, Nominal group technique, Multi-voting and Cause and effect diagram, Data collection and accuracy tools- Check sheet, Gauge R&R; Understanding and eliminating variation- run charts, control charts and process capability analysis; Analyze tools – Scatter plots, ANOVA, Regression analysis, Time trap analysis; Improve tools – Mistake proofing, Kaizen, set up time reduction (SMED), TPM, DOE and the pull system. Control tools – statistical process control.
UNIT V INSTITUTIONALIZING AND DESIGN FOR LSS
Institutionalizing lean six sigma – improving design velocity, creating cycle time base line, valuing projects, gating the projects, reducing product line complexity, Design for lean six sigma, QFD, Theory of Inventive Problem solving (TRIZ), Robust design; Case study presentations.
OUTCOMES:
CO1: The students will be able to understand what is Lean and Six sigma and their importance in the globalised competitive world.
CO2: The students will be able to understand the importance of integrating Lean and Six sigma and also the process of their integration.
CO3: The students will be able to plan the Resources required to undertake the LSS projects and also acquire how to select the suitable projects and the teams.
CO4: The students will be able apply DMAIC methodology to execute LSS projects and in this regard they will be acquainted with various LSS tools.
CO5: The students will be able to understand the process of institutionalizing the LSS effort and also understand the Design for LSS.
REFERENCES:
1. James P. Womack, Daniel T. Jones, Lean Thinking, Free press business, 2003.
2. Michael L. George, Lean Six Sigma, McGraw-Hill., 2002.
3. Ronald G.Askin and Jeffrey B.Goldberg, Design and Analysis of Lean Production Systems, John Wiley &Sons., 2003.
4. Salman Taghizadegan, Essentials of Lean Six Sigma, Elsevier, 2010.