SCI09005 2016 Lean Six Sigma and Operations Management

General Details

Full Title
Lean Six Sigma and Operations Management
Transcript Title
LSS&Ops Mgmt
100 %
Subject Area
SCI - Science
LIFE - Life Sciences
09 - NFQ Level 9
05 - 05 Credits
Start Term
2016 - Full Academic Year 2016-17
End Term
9999 - The End of Time
Stephen Daly
Programme Membership
SG_SBPRO_M09 201600 Master of Science in Bioprocessing SG_SBPRO_O09 201700 Postgraduate Diploma in Science in Bioprocessing SG_SBPRO_M09 201600 Master of Science in Bioprocessing

Operations Management in the Biopharma/Pharma industries details the methods, systems and tools used in management of products, processes, services and supply chains. Implementation of Lean and Six Sigma methodologies into manufacturing operations for the Biopharma and Pharma industries is now a common practice to ensure success and an effective continuous improvement environment.

This module provides an overiew of operations management incorporating the acquisition, development, and utilisation of resources needed to deliver supply on demand. As part of this it will demonstrate a number of lean six sigma tools which can be used to achieve this.



Learning Outcomes

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


Describe the strategic importance of operations, the capabilities and limitations of the operations function


Demonstrate an understanding of the concepts and methods related to designing and managing a Biopharma/Pharmaceutical operations facility including: a. The sequence of steps involved in bringing a product to market, from order confirmation, receipt of material through production to delivery shipment. b. Demand forecasting & planning, production scheduling & control methods c. Modern facility layout and process flow d. Technology transfer and project management


Develop a skillset for organizing activities as part of a project / process - from conception of system interrelation, to organize activities effectively, to analysing processes KPIs, continual process improvement.


Analyse the operations/system output and/or data using appropriate lean six sigma tools such as SPC, value stream mapping, visual management, experimental techniques and models and examine improvement methodologies; JIT


Evaluate and discuss the key principles of Lean Six Sigma Manufacturing and their typical applications
for bioprocess industries.


Demonstrate the application of Lean Six Sigma tools such as Value Stream Metrics, SMED, 5S,Visual Management, TPM, Kaizen Events, Risk Management, Creating Continuous Flow, Process Capability, FMEA and Error Proofing.


For a typical biopharmaceutical process demonstrate the application of a combination of Lean-Sigma tools for manufacturing operations.


Engage in and demonstrate independent learning as well as communicateeffectively as an individual and as a member of a team.

Teaching and Learning Strategies

This module can be taught using a combination of face to face and 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. Where possible a visit to an operation biopharma/pharma facility will be incorportated into the module for students to visualise a real life practical application. 

Module Assessment Strategies

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

Repeat Assessments

Students will need to liaise directly with the lecturer to determine repeat assessment requirements based on their performance throughout the module.

Indicative Syllabus

Topics covered from an operations management perspective will include product plan development, production and distribution, material reconciliation. Management Information Systems (MIS), MRP Scheduling, forecasting, inventory control. Suppliers/Contractor/Customer, relationship development, structure, auditing, delivery inspection process. Work instruction/documentation control, review and approval, SOPs. Facilities operations layout and process flow. 

Integration of Lean six sigma tools and methodologies into operations management will include DMAIC, Quality assurance and performance, Process capability CpK, OOE improvements, Problem solving, JIT - methods of organizations, Output SPC, KPI's, OTIF (customer satisfaction, deviations, rework, complaints), Total Quality Management, Process Flow manufacturing, Value Stream Mapping, FMEA and error proofing.

Coursework & Assessment Breakdown

Coursework & Continuous Assessment
60 %
End of Semester / Year Formal Exam
40 %

Coursework Assessment

Title Type Form Percent Week Learning Outcomes Assessed
1 MCQ 1 Continuous Assessment Multiple Choice 10 % Week 5 1,2,3
2 MCQ 2 Continuous Assessment Multiple Choice 10 % Week 10 4,5,6
3 Enquiry Project Continuous Assessment Group Project 20 % OnGoing 7,8
4 Project and Viva Project Project 20 % OnGoing 6,7,8

End of Semester / Year Assessment

Title Type Form Percent Week Learning Outcomes Assessed
1 End of Semester Exam Final Exam Closed Book Exam 40 % Week 13 1,2,3,4,5,6,7

Full Time Mode Workload

Type Location Description Hours Frequency Avg Workload
Lecture Lecture Theatre Lecture/Online Lecture 2 Weekly 2.00
Independent Learning Library Project work/Team Assignments 7 Weekly 7.00
Total Full Time Average Weekly Learner Contact Time 2.00 Hours

Module Resources

Non ISBN Literary Resources

Slack, N., Chambers, S., Johnston, R., Operations management. (6 th Ed). Prentice Hall England. 2010. ISBN 0273731602, 9780273731603

Mohan, P., Glassey, J., Montague, G., Pharmaceutical Operations Management: Manufacturing for Competitive Advantage. McGraw-Hill Education, 2006. ISBN 0071472495, 9780071472494

Chary, S. N., Production and operations management. Tata McGraw-Hill Education, 2009. ISBN 0070091536, 9780070091535

Womack, J.P and Jones, D.T., Lean Thinking, Free Press, 2003


George, M.L., Rowlands, D., Price, M., Maxey, J. The Lean Six Sigma Pocket Toolbook McGraw Hill. 2005. ISBN-13: 978-0071441193

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

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

Friedli, T et al., Operational Excellence in the Pharmaceutical Industry, Editio Cantor Verlag.,

Pyzdek, T., The Six Sigma Handbook, McGraw-Hill, 2003

URL Resources


Other Resources


Additional Information