INTR9028 - Lean Six Sigma Skills

Module Details

Module Code: INTR9028
Title: Lean Six Sigma Skills
Long Title: Lean Six Sigma Skills
NFQ Level: Expert
Valid From: Semester 1 - 2024/25 ( September 2024 )
Duration: 1 Semester
Credits: 5
Field of Study: 5213 - Interdisciplinary Engineering
Module Delivered in: 1 programme(s)
Module Description: This module will present lean six sigma skills & continuous improvement methodology that is applicable to modern manufacturing operations.
 
Learning Outcomes
On successful completion of this module the learner will be able to:
# Learning Outcome Description
LO1 Critique lean principles and six sigma tools & applications as a means of producing process and financial improvements in a manufacturing environment.
LO2 Critically analyse the DMAIC methodology (Define, Measure, Analyse, Improve and Control) within a work-based context
LO3 Analyze process data using appropriate statistical tools for the purpose of implementing lean, process improvement, and sustainability strategies.
LO4 Compare and reflect on the dynamics of teams and the role of leadership in an organisational setting of change.
LO5 Critically analyse the implementation of a Lean Sigma project.
Dependencies
Module Recommendations

This is prior learning (or a practical skill) that is strongly recommended before enrolment in this module. You may enrol in this module if you have not acquired the recommended learning but you will have considerable difficulty in passing (i.e. achieving the learning outcomes of) the module. While the prior learning is expressed as named MTU module(s) it also allows for learning (in another module or modules) which is equivalent to the learning specified in the named module(s).
Incompatible Modules
These are modules which have learning outcomes that are too similar to the learning outcomes of this module. You may not earn additional credit for the same learning and therefore you may not enrol in this module if you have successfully completed any modules in the incompatible list.
No incompatible modules listed
Co-requisite Modules
No Co-requisite modules listed
Requirements

This is prior learning (or a practical skill) that is mandatory before enrolment in this module is allowed. You may not enrol on this module if you have not acquired the learning specified in this section.
No requirements listed
 
Indicative Content
Lean Sigma Methodologies for Implementation
Lean principles and six sigma methodology, value and foundations of lean and six sigma. Six sigma and lean applications in manufacturing, service, design and innovation. Variability reduction and waste elimination. DMAIC framework & methodology, critical success factors, statistical techniques, measurement system analysis, hypothesis testing, regression, control charts, process capability. Design of experiments, lean sigma supply chain, standard work, leader standard work, 5s, Gemba, Shingo.
Lean Sigma Methodologies
Lean principles and Six Sigma methodology. Value and foundations of lean and six sigma. Six sigma and lean applications in manufacturing, service, design and innovation. Variability reduction and improvements in sustainability including waste elimination. The DMAIC framework.
Continual Improvement Tools:
Value stream mapping for process analysis. Flow charts/process mapping. Analyse current state and map, plan future state and map, implementation planning, failure mode and effect analysis, critical to quality and prioritization matrix, pareto analysis, affinity diagrams, root cause analysis and fishbone/ cause – effect diagrams.
Critical Interpersonal Skills for Lean Sigma Professionals
Communication: goals, objectives & benefits, overcome project resistance. Coaching: enablement of stakeholders to solve problems by themselves.
Organisational Change Management:
Lean philosophy, driving change: change management, facilitation, project control, return on investment, opportunities of changing and the threats of not changing. Conflict resolution. Time management. Negotiation techniques.
Lean Sigma Project Economics
Economic decision making, interest and rate of return techniques. Payback period, replacement decisions, capital investment decisions. Non-financial return evaluation.
Facilitating Project Teams
Team dynamics, team formation, team selection criteria, conflict resolution, organizing meetings for success.
Case Study:
Lean simulation for continuous improvement, capacity analysis, planning and scheduling.
Module Content & Assessment
Assessment Breakdown%
Coursework100.00%

Assessments

Coursework
Assessment Type Short Answer Questions % of Total Mark 25
Timing Week 4 Learning Outcomes 1,2
Assessment Description
Application of Lean Six Sigma Principles and DMAIC Methodology
Assessment Type Presentation % of Total Mark 30
Timing Week 7 Learning Outcomes 3,4
Assessment Description
Data driven team presentation on a process improvement and identification of waste reduction scenario. Focus is on lean, process improvement and waste reduction along with the selection of appropriate statistical tools. The team will be asked to reflect on the team dynamics in the preparation and delivery of the presentation.
Assessment Type Written Report % of Total Mark 45
Timing Week 13 Learning Outcomes 4,5
Assessment Description
Report on continuous improvement activity. Lean Simulation case study for Continuous Improvement, Capacity Analysis, Planning and Scheduling.
No End of Module Formal Examination
Reassessment Requirement
Coursework Only
This module is reassessed solely on the basis of re-submitted coursework. There is no repeat written examination.

The University reserves the right to alter the nature and timings of assessment

 

Module Workload

Workload: Full Time
Workload Type Contact Type Workload Description Frequency Average Weekly Learner Workload Hours
Lecture Contact Including theory, case studies, group work and worked scenarios Every Week 3.00 3
Independent & Directed Learning (Non-contact) Non Contact Study Every Week 4.00 4
Total Hours 7.00
Total Weekly Learner Workload 7.00
Total Weekly Contact Hours 3.00
Workload: Part Time
Workload Type Contact Type Workload Description Frequency Average Weekly Learner Workload Hours
Lecture Contact Including theory, case studies groupwork and worked scenarios Every Week 3.00 3
Independent & Directed Learning (Non-contact) Non Contact Study Every Week 4.00 4
Total Hours 7.00
Total Weekly Learner Workload 7.00
Total Weekly Contact Hours 3.00
 
Module Resources
Recommended Book Resources
  • Hutwelker Reiner. (2019), Six Sigma Green Belt Certification Project: Identification, Implementation and Evaluation., Springer, [ISBN: 9783030319144].
  • Roderick A. Munro,Govindarajan Ramu,Daniel J Zrymia. (2022), The ASQ Certified Six Sigma Green Belt Handbook Third Edition, ASQ Quality Press, p.0, [ISBN: 9781636940298].
Supplementary Book Resources
  • John Morgan,Martin Brenig-Jones. (2010), Lean Six Sigma For Dummies, John Wiley & Son, p.222, [ISBN: 9781119992264].
  • Gopal Ranjan,Tanmay Vora. (2014), Implementing Lean Six Sigma in 30 Days, Packt Publishing Ltd, p.140, [ISBN: 9781783000357].
This module does not have any article/paper resources
Other Resources
 
Module Delivered in
Programme Code Programme Semester Delivery
CR_ERNPI_9 Master of Science in Regulated New Product Introduction & Technology Transfer 2 Mandatory