EME 6673 – Six Sigma Processes

A. Leon Linton Department of Mechanical Engineering

Lawrence Technological University
Spring 2019

Course Information:
Course No.: EME 6673
Course Title: Six Sigma Processes
Lecture: Tuesday, 5:45 pm – 8:25 pm
Classroom: E209
Office hours: Tuesday, 4:30 – 5:30pm or by appointment
Internet site: Canvas my.ltu.edu

Faculty Information:
Ahad Ali, Ph.D.
Associate Professor
Director of Master of Science in Industrial Engineering (MSIE)
Director, Bachelor of Science in Industrial Engineering (BSIE)
Director, Smart Manufacturing and Lean Systems Research Group
A. Leon Linton Dept. of Mechanical Engineering
Phone: 248 204 2531, Fax: 248 204 2576, Office: E37
Email: [email protected]; Web page: http://vfacstaff.ltu.edu/aali/

Catalog Description:
The course will cover modern design tools and methods on the Six Sigma paradigm. Topics
include tools and methods including process flow diagrams, cause and effect diagrams, gage R&R,
organizational leadership, product development, system integration, critical parameter
management, quality function deployment, concept generation, and strategy for organizing six
sigma techniques in industry among many others. Provide useful tools to conceive new product
requirements, design baseline functional performance, optimize design performance, and verify
system capability.

References:
Six Sigma Statistics, Issa Bass, ISPN9780071496469.
The Certified Six Sigma Green Belt Handbook, Roderick A., Munro, Matthew J. Maio, Mohamed B.
Nawaz, Govindarajan Ramu, Daniel J. Zrymiak, ASQ Press, 2007.
Antony, J., Kumar, A. and Banuelas, R., World Class Applications of Six Sigma: Real World Examples
of Success, Butterworth-Heinemann; 1 edition, 2006.
Breyfogle, F. W. III, Implementing Six Sigma, John Wiley & Sons, Inc., 2003.
Cavanagh, R. R., Neuman, R. P. and Pande, P. S., The Six Sigma Way: How GE, Motorola and Other
Top Companies are Honing Their Performance.
Eckes, G., The Six Sigma Revolution. New York: John Wiley and Sons, Inc., 2001.
Gitlow, H. S. and Levine, D. M., Six Sigma for Green Belts and Champions, Pearson Education, 2005.

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Kubiak, T.M. and Benbow, D. W., The Certified Six Sigma Black Belt Handbook, 2nd Edition.
Munro, R. A., Maio, M. J. and Nawaz, M. B., Govindarajan Ramu, and Daniel J. Zrymiak, The Certified
Six Sigma Green Belt Handbook.
Pries, K. H. Six Sigma for the New Millennium: A CSSBB Guidebook, Second Edition.
Pyzdek, T. and Keller, P., The Six Sigma Handbook, Third Edition: A Complete Guide for Green Belts,
Black Belts, and Managers at all levels.

Objectives:
By the end of this course, you should be able to:
1. understand and describe the six sigma processes for continuous improvement
2. describe, select and use the DMAIC approach
3. explain and apply six sigma quality tools
4. establish six sigma baseline metrics and perform process improvement
5. comprehend quality function deployment
6. conduct a gauge R&R and do a process capability analysis
7. make effective product and process decisions using six sigma methodologies
8. demonstrate relevant computing technologies applications
9. complete a project and communicate the results and analysis through a detailed technical
report and presentation.

Six Sigma Topics

• Introduction to Six Sigma & DMAIC
• Six Sigma Body of Knowledge: Define, Measure, Analyze, Improve, and Control
(DMAIC)
• Describe, Idea Generation, select and use the DMAIC approach
• Apply Six Sigma quality tools
• Comprehend and apply Six Sigma measurement techniques
• 6σ SPC, Attributes Control Charts, Variables Control Charts
• Quality Function Deployment (QFD)
• Confidence Level and Hypothesis Tests
• Process Capability
• 6σ – Chi-Square Analysis
• 6σ – Benchmarking
• Gage R&R Analysis
• Visualization of Data

SIX SIGMA PROJECT

Six Sigma Project Selection and Planning

• Outline of Project Expectations/Entitlement
• Project Selection
• Determination of Project Scope
• Development of Project Charter
• Development of Project Business Case
• Team Selection and Development
Project Performance
• Baseline Current Process Performance

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 • Evaluate and Select Project Methodologies
• Establish Six Sigma Baseline Metrics
• Validate Measuring System
• Collect Data
• Analyze Data
• Perform Process Improvement Experiments
• Implement Improved Process

Project Completion and Presentation

• Determine Six Sigma Control Methodologies
• Implement Methodologies
• Measure Process Performance and Determine Project Financial Benefits
• Develop Written Project Report
• Develop Presentation
• Make Presentation

Grading Policy:
Homework, Class Participation and Case Study Presentations 25%, Midterms 25%, Project 50%
A 90, A- 87, B+ 84, B 81, B- 78, C+ 75, C 72, C- 69, D+ 66, D 63, D- 60, F < 60

Course Outlines:

Week Topics
1 Syllabus, Introduction to Six Sigma & DMAIC
2-4 Six Sigma Body of Knowledge: Define, Measure, Analyze, Improve, and Control
(DMAIC)
5 Describe, Idea Generation, select and use the DMAIC approach
6 Comprehend and apply Six Sigma measurement techniques, Gage R&R Analysis
7 6σ SPC, Attributes Control Charts, Variables Control Charts,
8 Case Study Presentation and Project Proposal
9 Apply Six Sigma quality tools, Visualization of Data
10 Quality Function Deployment (QFD), Confidence Level and Hypothesis Tests
11 Process Capability, 6σ – Chi-Square Analysis, 6σ – Benchmarking
12 Six Sigma Project Selection and Planning
13 Project Performance
14 Six Sigma Project Paper Review
15 Final Project Paper Submission and Presentation

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Six Sigma Related Resources:
• 12th Annual Lean Six Sigma & Process Improvement Summit, 2011
• 2010 Lean and Six Sigma Conference – ASQ, March 8-9, 2010, Phoenix, AZ
http://www.asq.org/conferences/six-sigma/
• American Society for Quality, http://www.asq.org/index.html
• ASQ Reliability Division, http://www.asq.org/reliability/index.html
• IEEE Reliability Society http://www.ieee.org/portal/site/relsoc
• IIE Quality Control/Reliability Division, http://www.iienet2.org/Landing.aspx?id=898
• Institute of Industrial Engineers, Six Sigma, Quality and Reliability,
http://www.iienet.org/
• International Journal of Lean Six Sigma
• International Journal of Quality & Reliability Management, Emerald
• International Journal of Quality, Statistics, and Reliability
• International Journal of Reliability, Quality & Safety Engineering, World Scientific Pub.
• International Journal of Six Sigma and Competitive Advantage
• International Society of Six Sigma Professionals (ISSSP), http://www.isssp.com/
• National Science Foundation (NSF) Industry University Cooperative Research Center for
Quality and Reliability Engineering, Rutgers University and Arizona State University,
http://coewww.rutgers.edu/~ie/qre/about.html
• Quality & Productivity Journal
• Six Sigma References from ASQ Store: http://www.asq.org/quality-press/search-
results/index.html?search_mode=keyword&search_query=six+sigma
• Some real-world applications http://www.amazon.com/World-Class-Applications-Six-
Sigma/dp/0750664592
• www.isixsigma.com