BIO08025 2019 LEAN SIGMA

General Details

Full Title
Transcript Title
N/A %
Subject Area
BIO - Bio Tech/Eng/Chem
LIFE - Life Sciences
08 - NFQ Level 8
05 - 05 Credits
Start Term
2019 - Full Academic Year 2019-20
End Term
9999 - The End of Time
Stephen Daly
Programme Membership
SG_SBIOP_E08 201900 Level 8 Certificate in Science in Biopharmaceutical Science SG_SBIOP_K08 201900 Bachelor of Science (Honours) in Biopharmaceutical Science.

This module examines all 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 Lean tools such as Value Stream Mapping, SMED, 5S, Visual Management, TPM, Kaizen Events, Creating Continuous Flow.


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


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

Teaching and Learning Strategies

This module can be taught via on-line lectures. A range of Computer-Aided Learning (CAL) packages are also used to support this module (e.g. Moodle, Adobe Connect, Panopto, Camtasia).

Students are provided with electronic materials for self-assessment and preparation for assessments/assignments. Self-directed, student-centred, independent learning is a core aspect through completion of module coursework.

Module Assessment Strategies

The assessment approach for this module will be 100% continuous employed including some of the following:
Enquiry based Projects (both individual and team based). Assignments/mini projects, short-form assessment exams incl. MCQs, Short answer and Long Answer Questions

Repeat Assessments

Students will have opportunities to re-submit work as agreed with their lecturer.

Indicative Syllabus

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

Coursework & Assessment Breakdown

Coursework & Continuous Assessment
100 %

Coursework Assessment

Title Type Form Percent Week Learning Outcomes Assessed
1 MCQ 1 Continuous Assessment Multiple Choice 10 % Week 5 1,2
2 MCQ 2 Continuous Assessment Multiple Choice 10 % Week 9 3,4
3 Assignment 1 Continuous Assessment Assignment 20 % Week 3 3,4
4 Assignment 2 Continuous Assessment Assignment 20 % Week 7 3
5 Assignment 3 Continuous Assessment Assessment 20 % Week 12 5
6 End of Semester Assessment Continuous Assessment Assessment 20 % Week 13 1,2,3,4,5

Part Time Mode Workload

Type Location Description Hours Frequency Avg Workload
Lecture Not Specified Online lecture. 2 Weekly 2.00
Directed Learning Not Specified Directed study of online materials. 3 Weekly 3.00
Independent Learning Not Specified Self-directed learning. 3 Weekly 3.00
Total Part Time Average Weekly Learner Contact Time 5.00 Hours

Required & Recommended Book List

Required Reading
2002-04-25 Lean Six Sigma McGraw-Hill
ISBN 0071385215 ISBN-13 9780071385213

Time and quality are the two most important metrics in improving any company's production and profit performance. Lean Six Sigma explains how to impact your company's performance in each, by combining the strength oftoday's two most important initiatives--Lean Production and Six Sigma--into one integrated program. The first book to provide a step-by-step roadmap for profiting from the best elements of Lean and Six Sigma, this breakthrough volume will show you how to: * Achieve major cost and lead time reductions this year * Compress order-to-delivery cycle times * Battle process variation and waste throughout your organization

Required Reading
2010-12-09 Lean Six Sigma Demystified, Second Edition Mcgraw-hill
ISBN 0071749098 ISBN-13 9780071749091

Your LEAN and mean guide to Lean Six Sigma Ready to implement better, faster, cheaper, more-profitable processes in your organization? Lean Six Sigma Demystified, Second Edition, shows you how to use proven techniques for simplifying, streamlining, and optimizing business practices for maximum productivity and profitability. Written in a step-by-step format, this practical guide covers the fundamental methods and tools of Lean Six Sigma. You'll get details on reducing defects and deviation, sustaining improvements, and achieving laser-focused process innovations. Measurement systems analysis (MSA), Design for Lean Six Sigma, and statistical tools such as analysis of variance (ANOVA) are also discussed. Clear examples, helpful diagrams, and concise explanations make it easy to understand the material, and end-of-chapter quizzes and a final exam reinforce key concepts. It's a no-brainer! You'll learn about: The seven speed bumps of Lean Value stream mapping and spaghetti diagramming Control charts, Pareto charts, and Ishikawa diagrams to laser-focus improvements Excel power tools for Lean Six Sigma Lean Six Sigma tar pits Ways to implement Lean Six Sigma to maximize results and minimize costs Simple enough for a beginner, but challenging enough for an advanced student, Lean Six Sigma Demystified, Second Edition, is your shortcut to this powerful improvement methodology. You'll also get a 90-day free trial of Q1 Macros software for Lean Six Sigma.

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

See Moodle Page

URL Resources

See Moodle Page

Other Resources


Additional Information