BIO07025 2019 LEAN SIGMA

General Details

Full Title
Transcript Title
N/A %
Subject Area
BIO - Bio Tech/Eng/Chem
LIFE - Life Sciences
07 - NFQ Level 7
05 - 05 Credits
Start Term
2019 - Full Academic Year 2019-20
End Term
9999 - The End of Time
Mary Butler, Paul Walsh, Ailish Breen
Programme Membership
SG_SBIOP_J07 201900 Bachelor of Science in Science in Biopharmaceutical Science SG_SBIOE_E07 201900 Certificate in Science in Bioprocess Engineering L7

This module examines various aspects of the application of Lean Processing and Six Sigma principles and tools as they apply to the modern manufacturing environment.

Learning Outcomes

On completion of this module the learner will/should be able to;


Evaluate and discuss the key principles of Lean Manufacturing and their typical applications for manufacturing.


Evaluate and discuss the key principles of Six Sigma programmes and their typical applications for manufacturing. 


Demonstrate the application of typical Lean tools such as Value Stream Mapping, SMED, 5S, Visual Management, TPM, Kaizen Events, Creating Continuous Flow.


Demonstrate the application of typical Six Sigma tools such as DMAIC, Process Centering and Variation Reduction, SPC, FMEA, Poka-Yoke, ANOM, ANOVA.


For a typical manufacturing operation demonstrate the practical application of a combination of Lean-Sigma tools.

Teaching and Learning Strategies

Lectures will be taught online.  Content and extra reading will be provided in advance via the moodle page.  Other online resources such as videos, software, blog sites will be used as appropriate.

Module Assessment Strategies

A variety of online assessment tools and strategies will be employed as part of this module including online quizzes and assignments - there will also be an end-of-term written exam for this module. 

Repeat Assessments


Indicative Syllabus

Topics covered will include the following: Introduction to Lean Principles - Creating Continuous Flow for Processes. 5S Programme and Visual Management Techniques. TPM - Total Productive Maintenance. Introduction to Six Sigma Principles. DMAIC approach to problem solving. Value Stream Mapping for Processes. SMED (Quick Changeover Techniques). Process Centering and Variation Reduction. SPC (Statistical Process Control) and Process Capability Analysis. Application of analytical tools such as Pareto, SPC, Scatter plots, FMEA, Poka-Yoke (mistake-proofing), Analysis of Means (ANOM), Analysis of Variance (ANOVA), A3 reporting.

Coursework & Assessment Breakdown

Coursework & Continuous Assessment
50 %
End of Semester / Year Formal Exam
50 %

Coursework Assessment

Title Type Form Percent Week Learning Outcomes Assessed
1 Multiple Choice Questions Continuous Assessment Assessment 10 % Week 6 1,2
2 Multiple Choice Questions Continuous Assessment Assessment 10 % Week 12 3,4
3 Written Assignment Continuous Assessment Assignment 30 % Week 10 5

End of Semester / Year Assessment

Title Type Form Percent Week Learning Outcomes Assessed
1 Final Exam written end-of-term exam paper. Final Exam Closed Book Exam 50 % End of Term 1,2,3,4

Part Time Mode Workload

Type Location Description Hours Frequency Avg Workload
Lecture Not Specified Online lecture 1 Weekly 1.00
Directed Learning Not Specified Directed study of online materials. 2 Weekly 2.00
Independent Learning UNKNOWN Self-directed learning. 3 Weekly 3.00
Total Part Time Average Weekly Learner Contact Time 3.00 Hours

Module Resources

Non ISBN Literary Resources

George, M.L., Maxey J., Rowlands, D. and Upton M. 'The Lean Six Sigma Pocket Toolbook'. McGraw-Hill Professional, 2005.

Womack, J.P and Jones, D.T., 'Lean Thinking', Free Press, 2003.

Balle, F and Balle, M., 'The Gold Mine: a Novel of Lean Turnaround', Lean Enterprise Institute, 2005.

Bicheno, J., The Lean Toolbox, Piscie Books, 2004.

Friedli, T et al., 'Operational Excellence in the Pharmaceutical Industry', Editio Cantor Verlag., 2006.

Pyzdek, T., 'The Six Sigma Handbook', McGraw-Hill, 2003.

Journal Resources


URL Resources


Other Resources


Additional Information