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
Tools for definition – IPO diagram, SIPOC diagram, Flow diagram, CTQ Tree, Project Charter – Tools for measurement – Cause and effect diagram, Pareto charts, Control charts, Flow process charts, Tools for analysis – Process Mapping, Regression analysis, SWOT, PESTLE, Five Whys, interrelationship diagram, overall equipment effectiveness – Tools for improvement – Affinity diagram, Normal group technique, SMED, 5S, mistake proofing, Value stream Mapping – Tools for control – Gantt chart, Activity network diagram, Radar chart, PDCA cycle
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
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
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
Reference Book:
1. Michael L.George, David Rownalds, Bill Kastle, What is Lean Six Sigma, McGraw – Hill 2003 2. Forrest W. Breyfogle, III, James M. Cupello, Becki Meadows, Managing Six Sigma:A Practical Guide to Understanding, Assessing, and Implementing the Strategy That Yields Bottom-Line Success, John Wiley & Sons, 2000 3. Fred Soleimannejed , Six Sigma, Basic Steps and Implementation, AuthorHouse, 2004 4. James P. Womack, Daniel T.Jones, Lean Thinking, Free Press Business, 2003
Text Book:
Thomas Pyzdek, The Six Sigma Handbook, McGraw-Hill,2000
