QLTY07030 2019 Six Sigma 1 - Introduction to Lean Sigma Quality

General Details

Full Title
Six Sigma 1 - Introduction to Lean Sigma Quality
Transcript Title
Six Sigma 1 - Introduction to
N/A %
Subject Area
QLTY - Quality
MECT - Mechatronics
07 - NFQ Level 7
05 - 05 Credits
Start Term
2019 - Full Academic Year 2019-20
End Term
9999 - The End of Time
Brian Coll
Programme Membership
SG_EPLYP_J07 201900 Bachelor of Engineering in Engineering in Polymer Processing SG_EDATA_J07 201900 Bachelor of Engineering in Engineering in Data Centre Facilities Engineering SG_SQUAL_J07 201900 Bachelor of Science in Science in Quality SG_EMANM_J07 201900 Bachelor of Engineering in Engineering in Manufacturing Management SG_ESSYB_E07 201900 Certificate in Engineering in Six Sigma Yellow Belt SG_ELSIG_S07 201900 Level 7 Certificate in Engineering in Lean Sigma Quality SG_EPOLY_B07 201900 Bachelor of Engineering SG_EDATA_J07 202100 Bachelor of Engineering in Engineering in Data Centre Facilities Engineering

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. 

Learning Outcomes

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


Describe why organisations use Six Sigma and the Design for Six Sigma (DFSS) and DMAIC improvement methodology.


Define and describe Lean concepts and tools


Define, select and use the seven quality tools for problems solving, prioritising problems and improving processes. eg. Cause & Effect, Scatter Plots and Pareto charts.


Define, select and use the seven (new) management and planning tools. eg. Affinity diagrams, matrix diagrams and tree diagrams


Generate FMEAs and understand how they are used in risk management.


Calculate process performance metrics such as DPU, FTY, DPMO and Cost of Poor Quality (COPQ).


Collect and summarise data using surveys, descriptive and inferential statistics and graphical methods.

Teaching and Learning Strategies

The online teaching and learning strategy will follow the guidelines as developed by Quality Matters:  http://www.qmprogram.org/

Unique to the Quality Matters Rubric is the concept of alignment. This occurs when critical course components - Learning Objectives (2), Assessment and Measurement (3), Instructional Materials (4), Learner Interaction and Engagement (5), and Course Technology (6) - work together to ensure students achieve desired learning outcomes. 

Module Assessment Strategies

Assessment will be through a series of continuous assessments and a final exam. These will include the use of Quizzes and Minitab assignment submissions via our online learning management system Moodle.

Repeat Assessments

Resubmission of failing elements of the assessments. 

Indicative Syllabus

Overview: Six Sigma and the Organisation

A. Six sigma and organisational goals

•  Value of six sigma

•  Recognize why organisations use six sigma, how they apply its philosophy and goals, and the origins of six sigma (Juran, Deming, Shewhart, etc.). Describe how process inputs, outputs, and feedback impact the larger organization.

• Organisational drivers and metrics

• Recognise key drivers for business (profit, market share, customer satisfaction, efficiency, product differentiation) and how key metrics and scorecards are developed and impact the entire organisation.

•  Organizational goals and six sigma projects

•  Describe the project selection process including knowing when to use six sigma improvement methodology (DMAIC) as opposed to other problem-solving tools, and confirm that the project supports and is linked to organisational goals. Understand the roles and responsibilities of six sigma team members (i.e., individual team members, yellow belt, green belt, black belt, process owner, champion and sponsor.)

 B. Lean principles in the organisation

• Lean concepts and tools

• Define and describe concepts such as value chain, flow, pull, perfection, visual management and tools commonly used to eliminate waste, including kaizen, 5S, error-proofing, value-stream mapping, standardised work and TPM.

• Identify the difference between value-added and non-value-added activities

• Identify the seven wastes in terms of excess inventory, space, test inspection, rework, transportation, storage, and reducing cycle time to improve throughput.

• Describe the Theory of constraints 

C. Design for Six Sigma (DFSS) in the organisation

• Quality function deployment (QFD)

• Describe how QFD fits into the overall DFSS process.

• Define and distinguish between design FMEA (DFMEA) and process (PFMEA) and interpret associated data.

• Road maps for DFSS

• Describe and distinguish between DMADV (define, measure, analyze, design, verify) and identify how it relates to DMAIC and how it helps close the loop on improving the end product/process during the design (DFSS) phase. 

II. Six Sigma - Define

A. Process Management for Projects

• Process elements

• Define and describe process components and boundaries. Recognise how processes cross various functional areas and the challenges that result for process improvement efforts.

• Owners and stakeholders

• Identify process owners, internal and external customers, and other stakeholders in a project.

• Identify customers

• Identify and classify internal and external customers as applicable to a particular project, and show how projects impact customers.

• Collect customer data

• Use various methods to collect customer feedback (e.g., surveys, focus groups, interviews, observation) and identify the key elements that make these tools effective. Review survey questions to eliminate bias, vagueness, etc.

• Analyse customer data

• Use graphical, statistical, and qualitative tools to analyse customer feedback.

• Assist in translating customer feedback into project goals and objectives, including critical to quality (CTQ) attributes and requirements statements. Use voice of the customer analysis tools such as quality function deployment (QFD) to translate customer requirements into performance measures.


C. Management and planning tools

• Define, select, and use the following quality tools:

  1. Brainstorming and affinity diagrams, (5 Why - 1 How analysis)
  2. interrelationship diagraphs,
  3. tree diagrams,
  4. prioritisation matrices,
  5. Force Field Analysis and matrix diagrams,
  6. process decision program (PDPC) charts, and
  7. activity network diagrams
  8. Gantt Charts and Work Breakdown Structure (WBS)

D. Business results for projects

• Process performance

• Calculate process performance metrics such as defects per unit (DPU), rolled throughput yield (RTY), cost of poor quality (COPQ), defects per million opportunities (DPMO) sigma levels and process capability indices.

• Track process performance measures to drive project decisions.

• Failure mode and effects analysis (FMEA)

• Define and describe failure mode and effects analysis (FMEA). Describe the purpose and use of scale criteria and calculate the risk priority number (RPN).

 III. Six Sigma - Measure

A. Process analysis and documentation

• Process modeling

• Develop and review process maps, written procedures, work instructions, flowcharts, etc.

• Identify process input variables and process output variables. Use (SIPOC) (suppliers, inputs, process, outputs, and customers) to identify and define important elements of a process.

B. Collecting and summarising data

• Types of data and measurement scales. Define and distinguish between qualitative and quantitative types of data.

• Identify and classify continuous (variables) and discrete (attributes) data. Describe and define nominal, ordinal, interval, and ratio measurement scales.

• Data collection methods

• Define and apply methods for collecting data such as check sheets, coded data, etc.

• Techniques for assuring data accuracy and integrity

• Define and apply techniques such as random sampling, stratified sampling, sample homogeneity, etc.

• Descriptive statistics

• Define, compute, and interpret measures of dispersion (Standard deviation, range, variance) and central tendency (mean, median, mode), and construct and interpret frequency distributions and cumulative frequency distributions.

• Graphical methods and charts.

• Depict relationships by constructing, applying and interpreting diagrams and charts such as stem-and-leaf plots, box-and-whisker plots, run charts, scatter diagrams, correlation and regression Analysis and Pareto charts.

• Depict distributions by constructing, applying and interpreting diagrams such as histograms. Describe how the Histogram shape (skewed and bimodal) can affect data interpretation.

• Introduction to SPC and Control Charts

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 Moodle Online and Offline Assignments and Quiz submissions Continuous Assessment Assignment 50 % OnGoing 1,2,3,4,5,6,7

End of Semester / Year Assessment

Title Type Form Percent Week Learning Outcomes Assessed
1 Final Exam Final Exam Open Book Exam 50 % End of Semester 1,2,3,4,5,6,7

Full Time Mode Workload

Type Location Description Hours Frequency Avg Workload
Lecture Lecture Theatre Lecture 4 Weekly 4.00
Total Full Time Average Weekly Learner Contact Time 4.00 Hours

Part Time Mode Workload

Type Location Description Hours Frequency Avg Workload
Independent Learning Not Specified Moodle 4 Weekly 4.00
Lecture Distance Learning Suite Theory 2 Weekly 2.00
Tutorial Distance Learning Suite Tutorial 2 Weekly 2.00
Total Part Time Average Weekly Learner Contact Time 4.00 Hours

Required & Recommended Book List

Required Reading
2017 Lean Six Sigma and Minitab (5th Edition): The Complete Toolbox Guide for Business Improvement OPEX Resources Ltd
ISBN 095468138X ISBN-13 9780954681388
Recommended Reading
2011-01-06 Six Sigma Demystified, 2nd Edition McGraw-Hill
ISBN 007174679X ISBN-13 9780071746793

Learning Six Sigma CAN be a painless process!

Six Sigma is among the most effective process methods used today--and it's also among the most baffling topics to those new to the subject.

The good news is Six Sigma DeMYSTiFieD, second edition, explains it all in a language you'll understand. This easy-to-understand reference teaches the methods of Six Sigma, explains their applications, and tests expertise--without confusing statistics and formulas. In no time, you'll develop the skills you need to solve problems, anticipate customer needs, and meet the demands of the most challenging markets.

Filled with practical hands-on advice and essential organizational tips, Six Sigma DeMYSTiFieD provides a complete blueprint for developing strategies, plotting growth, and performing at peak efficiency for maximum profits.

This fast and easy guide offers:

  • Proven techniques for building a solid Six Sigma infrastructure
  • Tips for deploying projects using DMAIC methodology
  • Clear advice on when and how to use specific problem-solving tools
  • Essential calculations and assumptions
  • Case studies, quizzes, and a final exam that reinforce what you've learned

Simple enough for a beginner but challenging enough for a more advanced student, Six Sigma DeMYSTiFieD is your shortcut to a solid foundation in this powerful improvement methodology.

Recommended Reading
2008-01-01 The Certified Six Sigma Green Belt Handbook, First Edition ASQ Quality Press
ISBN 087389698X ISBN-13 9780873896986

ASQ's brand new Six Sigma Green Belt Certification is here - and this is the book to help prepare! This latest entry in ASQ's popular series of handbooks explicitly follows the certification's Body of Knowledge and addresses each topic to exactly the level Green Belts need. From lean and project management to statistics and data analysis, the DMAIC process is explained in a clear and insightful manner. Figures, tables, references, useful appendices, and a full sample test only add to this book's comprehensiveness. ***A new edition is available.

Module Resources

Non ISBN Literary Resources





Quentin Brook

Lean Six Sigma and Minitab: The Complete Toolbox Guide for Business Improvement

OPEX Resources Ltd



Munro et al

The Certified Six Sigma Green Belt handbook

ASQ Quality Press


Paul A. Keller

Six Sigma Demystified 2nd edition


McGraw-Hill Professional 2011





Journal Resources

International Journal of Lean Six Sigma

URL Resources

Listed on Moodle course Page

Other Resources

Listed on Moodle course page

Additional Information

Sample workshops for Full-time students:

  • Workshop 1 - Control Charts Simulation - Red Bead Experiment
  • Workshop 2 - Lean Simulation - Plug Game

Each workshop will run for 4 hours.