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Introduction to Six Sigma DMAIC (Define, Measure, Analyse, Implement & Control) Problem Solving Methodology

Status: Register Your Interest


Level

N/A

Duration

10 Weeks

Department

Mechanical & Automobile Engineering


Start Date

TBC

Course Type

Flexible & Professional

Location

Limerick

This module will introduce the learner to the Six Sigma DMAIC (Define, Measure, Analyse, Implement and Control) problem solving methodology. This module is aimed at gaining an ASQ yellow belt qualification and will also include some of the materials appropriate to gaining an ASQ green belt qualification. Through the completion of the module, learners will understand the structure and functioning of six sigma project teams, the roles of different team members and how they work in an advanced manufacturing environment.

What are the entry requirements?

Industry experience in a manufacturing environment with competence in process measurement. For example, those with a toolmaking trade or similar who understand measurements and have a Level 6 maths standard. 

An adequate level of English is also required for this course. 

Who can I contact?

What modules will I study?

This short programme is to introduce those with a Level 6 standard of knowledge into the area of Six Sigma and problem-solving methodology. The content is set at American Society of Quality Green belt level and will include content from that highly regarded industry standard. 

Course Content: 

Introduction to Lean Manufacturing

Purpose of lean manufacturing, lean concepts and tools (just-in-time, poka-yoke, Kanban, process mapping, value stream mapping, 5S, Kaizen, kaizen blitz), Deming's wheel of continuous improvement (Plan-Do-Check-Act); value add and non-value add activities; root cause analysis.

Introduction to Six Sigma

DMAIC methodology; project selection; voice of the customer; critical to quality (CTQ) characteristics; quality function deployment (QFD); SIPOC diagrams; design for six sigma (DFSS); six sigma team rols and responsibilities; six sigma metrics (defects per units(DPU)), defects per million opportunities (DPMO), rolled throughput yield (RTY), cycle time and cost of poor quality (COPQ); cost analysis.

Introduction to Six Sigma Project Management

DMAIC methodology; project selection; voice of the customer; critical to quality (CTQ) characteristics; quality function deployment (QFD); SIPOC diagrams; design for six sigma (DFSS); six sigma team roles and responsibilities; six sigma metrics (defects per units (DPU), defects per million opportunities (DPMO), rolled throughput yield (RTY), cycle time and cost of poor quality (COPQ); cost analysis.

Team Tools and Communication

Brainstorming; nominal group technique; flowcharts, check lists, effective communication techniques; presentation skills and writing, project status reports, multivoting, use of agendas and meeting minutes. 

Descriptive Statistics

Rules for collecting data; types of data (qualitative and quantitative, attribute and variable); data collection techniques (surveys, interviews, check sheets); measures of central tendency (mean, trimmed mean, median, mode); measures of variation (range, variance, standard deviation); measures of relative standing; graphical analysis tools (bar charts, histograms, pie charts); basic statistical tools (pareto charts, scatter diagrams, run charts, box plot, stem and leaf plot).

Introduction to Inferential Statistics

Application of statistical techniques in precision engineering; probability distributions (normal and binomial); empirical rule; central limit theorem; random variables; common cause and special variation; Minitab; design, utilise and interpret statistical process control charts; process control charts for continuous data (X-Bar &R, X-Bar & S and IMR); process control charts for attribute data (c,u,p and np), process capability indices (Cp, Cpk, Pp, Ppk), introduction to hypothesis testing (1 Sample Z-Test, 1 Sample T-Test, 2 Sample T-Test, Paired T-Test); power; simple linear regression and correlation.

Measurement Systems Analysis

Gauge reliability and reproducibility, linearity and bias, gauge R&R for destructive testing, attribute gauge R&R study, precision tolerance ratio (P/T).

Are there opportunities for further study?

Students who complete this programme may be eligible to take the ASQ green belt examination depending on their experience and qualifications. This programme may also be used for Recognition of Prior Learning and Continuous Professional Development (CPD) in the engineering sector. 

What are the career prospects?

Roles in quality control, process supervision in a manufacturing environment.

More Information

Delivery

Computer laboratory based with some practical measurement and data gathering.

10 weeks, 2.5 hours per week.

Wednesday evenings from 7.00pm to 9.30pm.

Materials - are materials required that the student must purchase themselves?

Students may want to purchase a student licence for minitab for home use. 

Assessment

A series of in class assignments and exercises will form the basis of assessment.

Qualification

Introduction to Six Sigma DMAIC Problem Solving Methodology

Application Deadline

TBC for 2022-23

For queries relating to the course content

Contact: Jennifer Hennessy

Email: Jennifer.hennessy@TUS.ie

Fees

€400