Lectures, in class simulations, video observation exercises and case analyses requiring extensive interaction with other students and instructor.
- Process and quality fundamentals, including: introduction to Total Quality Management (TQM); Just in Time (JIT); Lean; Six Sigma; ISO; and Plan-do-check-act (PDCA)
- Design principles and techniques, including: the choice of manufacturing environments, production processes, and layouts; batch versus flow process implications; and push versus pull principles
- Introduction to the DMAIC quality improvement framework
- Define phase tools: Supplier-Input-Process-Output-Customer (SIPOC) diagrams; voice of the customer; Quality Functional Deployment (QFD); and current state Value Stream Map (VSM)
- Measure phase tools: basic principles of measurement including reliability and validity of data as well as overview of statistical methods; descriptive statistics, run charts; process capability analysis; and dashboards & balanced scorecards
- Analyze phase tools: the 7 Basic Quality Tools (cause-and-effect diagrams, check sheet, control charts, histogram, pareto charts, scatter diagram, stratification); A3 problem solving; and regression and correlation analysis of root causes
- Improve phase tools: creating flow through the use of Takt time, Line Balancing, Heijunka; implementing pull through the use of Kanbans and Standard Work; and Mistake Proofing through the use of Visual Management and 5S
- Control phase tools: Visual Management and Failure Mode Effect Analysis (FMEA)
- Enabling a culture of continuous improvement
After completing this course, successful students will be able to:
• analyze basic execution and control systems and techniques in the operations management field;
• examine the system wide implications of process flow and methods for achieving a smooth flow;
• defend the importance of data collection in measuring performance and perform statistical analysis to monitor processes and identify trends;
• design a project using process improvement principles to analyze a current situation, identify opportunities for improvement and recommend a well thought out implementation plan;
• use of Lean and Six Sigma tools and discuss the role culture, customers and employee involvement plays; and
• solve Lean and Six Sigma Green Belt exam questions.
Group Improvement Project(s) 20 - 35%
Assignments 15 - 20%
Participation 0 - 10%
Midterm 15 - 25%
Final 25 - 35%
Textbooks and Materials to be Purchased by Students: Custom publication with relevant readings, cases and chapters taken from textbooks such as:
- Gitlow, Howard, R.J. Melnyck, D.M. Levine, Guide to Six Sigma and Process Improvement for Practitioners and Students: Foundations, DMAIC, Tools, Cases, and Certification. Latest Edition (Pearson FT Press)
- Cudney, Elizabeth, R. Kestle, Implementing Lean Six Sigma throughout the Supply Chain: The Comprehensive and Transparent Case Study. Latest Edition (Productivity Press)
or any alternative textbook/s approved by the Business Department