Revised 5/26

IND 123 - Introduction to Lean Manufacturing and Six Sigma (1 CR.)

Course Description

Covers basic Lean and Six Sigma concepts. Examines the importance of Lean and Six Sigma as pertaining to the world of manufacturing. Provides students with the opportunity to demonstrate the impact of Lean and Six Sigma manufacturing environment. Lecture 1 hour, Total 1 hour per week.

General Course Purpose

This course is designed to enable students to analyze, apply, evaluate, and implement Six Sigma and Lean Manufacturing principles, methodologies, and tools used to improve quality, operational efficiency, and continuous improvement in modern industrial and business environments. Students will examine Six Sigma philosophy, Lean concepts, DMAIC methodology, statistical analysis, process improvement techniques, waste reduction strategies, team development practices, and quality control systems. Through the study of topics such as 5S, Kaizen, Kanban, Poka-Yoke, Design of Experiments (DOE), hypothesis testing, and project control methods, students will analyze processes, identify inefficiencies, interpret data, develop improvement strategies, implement data-driven solutions, and evaluate methods for sustaining operational excellence in manufacturing and service organizations.

Course Prerequisites/Corequisites

None.

Course Objectives

Upon completing the course, the student will be able to:

• Define “Six Sigma.”
• Enumerate the core concepts of Six Sigma philosophy.
• Distinguish between consumers, external customers, and internal customers.
• List the 5 areas of 5S and explain the benefits of 5S.
• Describe Six Sigma as a quality system.
• Analyze the statistical definition of Six Sigma.
• Explain and calculate dpmo for a specific case.
• Distinguish between Six Sigma and Lean Manufacturing.
• Expand the acronym DMAIC and explain each term.
• Define Lean and list the goals of Lean Manufacturing.
• Enumerate the benefits of Lean Manufacturing.
• List the eight deadly wastes.
• Describe the House of Lean Manufacturing.
• Define Just-In-Time, Lead Time, Jidoka, Kanban
• Discuss the foundation and the two pillars of Lean Manufacturing.
• Define Lean Production (Just-In-Time) and explain it benefits.
• Define Lead Time and explain its benefits.
• Describe Process Cycle Time and its importance.
• Define Takt Time and explain its importance.
• Describe the functions of a Kanban system and its benefits.
• Describe the four types of Kanban systems.
• Define the term kaizen and its role in lean manufacturing.
• Describe the three phases of a kaizen event and how to implement the results of a kaizen event.
• Define the principles of Tuckman’s Team Development.
• Describe how a Six Sigma team is created.
• Define Poka-Yoke and explain its role.
• Describe the elements of a Poke-Yoke system.
• Describe the main goal of the measure phase of a Six Sigma project.
• Describe the types of data collected for a Six Sigma project.
• Describe the basic statistics used in a Six Sigma project.
• Describe the elements of an effective measurement system.
• Describe the analysis phase of a Six Sigma Project.
• Define descriptive analysis.
• Define hypothesis testing and basic concepts of hypothesis testing.
• Define the terms mean, mode, standard deviation and ANOVA.
• Describe the goals of the improvement phase of a project.
• Describe the tools used to help implement and validate improvement ideas.
• Describe the steps of a design of experiment (DOE).
• Define basic DOE terms: variable, process, analysis and error.
• Describe the goals and activities of the control phase of a project.
• Describe how to close out a Six Sigma project.

Major Topics to Be Included

Critical attention will be given to the following topics:

• Six Sigma Methodology
• Workplace Organization: 5S
• Lean Six Sigma Principles
• Lean Manufacturing
• Lean Production and Kanban System
• Lean Processes
• Total Productive Maintenance (TPM)
• Kaizen
• Team Development and Management
• Poka-Yoke
• Measurement and Analysis
• Improvement and Control