UNIT-I Lean and 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. (Chapter - 1) 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. (Chapter - 2) 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. (Chapter - 3) 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. (Chapter - 4) 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. (Chapter - 5)
