Six Sigma 1 ‑ Introduction to Lean Sigma quality aims to provide learners with an understanding of the tools and techniques of quality that are used in the attainment of a six-sigma quality environment. The principal goal of Six Sigma is to reduce variation in the process and improve quality. Through practical examples and exercises, learners will become proficient in the use of the basic problem-solving techniques used to monitor and control processes. The topics include: the Six Sigma DMAIC problem-solving process, Lean principles, FMEA's and risk management, the seven traditional quality tools, surveys, descriptive statistics and an introduction to inferential statistics. The module now includes lectures on Minitab – the industry-leading Six Sigma statistical software.

This module is also designed to meet the requirements of the Six Sigma Yellow belt award. This module aligns with the internationally recognised Six Sigma Green Belt body of knowledge from the American Society for Quality (ASQ) and also from Quality America.

As this is an online course, the majority of students are working in industry.

1. Describe why organisations use Six Sigma andthe Design for Six Sigma (DFSS) and DMAIC improvement methodology.
2. Define and describe Lean concepts and tools
3. Define, select and use the seven quality tools for problems solving, prioritising problems and improving processes. eg. Cause & Effect, Scatter Plots and Pareto charts.
4. Define, select and use the seven (new) management and planning tools. eg. Affinity diagrams, matrix diagrams and tree diagrams
5. Generate FMEAs and understand how they are used in risk management.

6. Calculate process performance metrics such as DPU, FTY, DPMO and Cost of Poor Quality (COPQ).
7. Collect and summarise data using surveys, descriptive and inferential statistics and graphical methods.

This module aims to provide learners with the statistical tools associated with the six sigma DMAIC philosophy specifically in the areas of Measure, Improve and control consistent with the ASQ and Quality America Green Belt Body of Knowledge. The student will be able to perform basic statistical analysis, develop and plots control charts, determine process and measurement capability. Minitab statistical software will be used to demonstrate and apply these statistical techniques.

1. Perform basic probability calculations by applying the probability rules and concepts
2. Describe and interpret the common probability distributions
3. Calculate, analyse and interpret measurement systems
4. Perform process capability and process perfromance analysis and interpret the results.
5. Perform exploratory data analysis using multi-vari charts, correlation and simple regression
6. Perform basic hypothesis testing eg. Hypothesis testing of means
7. Perform one way analysis of variance
8. Describe the experimental design terms and process
9. Develop control charts for variable and attribute data and interpret the results
10. Develop control charts with Minitab
11. Use the six sigma tools to implement control and monitoring systems

During this course, we will study the application of Lean and Operational Excellence (OpEx) principles, including the Shingo model for operational excellence.

Lean is widely considered to originate from the world-class manufacturing techniques of the Japanese auto industry and in particular the Toyota Production System (TPS). Lean and OpEx been embraced by leading global companies in the manufacturing and service sectors and are now the foremost process improvement approach for organisations that wish to attain world-class performance in quality and customer satisfaction by eliminating 'waste' in their processes. In Lean terms 'waste' refers to anything that does not add value to the product or service in the eyes of the customer.

The Lean tools are a key component and enabler of Operational Excellence where problem-solving, teamwork and leadership results in continuous improvement in the workplace. Although originating in manufacturing, the Lean tools and techniques are also being used in healthcare, banking and government sectors where benefits have been achieved in productivity, efficiency, and cost reduction.

1. Describe the key principles of Lean and Operational Excellence (OpEx) and how theycan be used to drive continuous improvement and competitive advantage in an organisation. e.g. Lean transformation, Strategy deployment.

2. Recognise the potential sources of waste in a process and identify the appropriate Lean tool(s) to measureand reduce/eliminate that waste. e.g. Leader Standard Work (LSW), Audits, Gemba waste elimination walks.

3. Demonstrate the application of typical Lean tools such as Value Stream Mapping,SMED, Error Proofing, 5S, Visual Management, TPM, Kaizen Events, in creating a continuous flow.

4. Identify and use the appropriate metrics and Key Performance Indicators (KPIs)to improve process performance in terms of quality, throughput, productivity and cost. e.g. Yield, Lead time, Cycle time, Downtime and Efficiency.

5. Demonstrate the use of problem-solving tools such as 5-Whys, Brainstorming, Cause & Effect (Fishbone)andA3sheets in Root Cause Analysis (RCA).

The project aims to provide students with the opportunity to apply and integrate the skills and knowledge they have gained on the programme.

For students in employment, the project should address a substantive issue in the workplace. The project will test the student's ability to define a real-life problem of concern to the organisation, design a strategy for addressing the problem, gather data, formulate and evaluate options and make recommendations. The project must follow the DMAIC problem-solving methodology using Lean and/or Six Sigma tools.

For students not in employment and unable to complete a work-based project, then a simulated Lean Six Sigma project option may be undertaken. This will consist of reviewing six sigma case studies, analysing the data and using the appropriate Six Sigma tools and Minitab statistical software to identify the solutions to the problem.

A mentor will be assigned to each project, which may be individual or in some cases group projects. The mentor will act as a guide in agreeing the relevance, and scope of the project and monitor the progress on a regular basis. There will be regular contact between the student and their mentor as the project progresses throughout the semester. Updates will be sent to the mentor on an agreed basis.

1. Identify a problem which needs to be addressed of importance to the organisation.
2. Utilise an appropriate structured approach to manage the project with realistic, interim and overall project objectives.
3. Identify and use the appropriate Lean Six Sigma tools to address the problem and implement the required solution(s).

4. Present project results with Executive Summary, Conclusions and Recommendations and justify the approach that was taken and the results achieved.