Six Sigma Principles & Methods

BUS MGT 4250

Six Sigma Principles & Methods

Autumn 2017

Instructor: Douglas Evans

Office: Fisher 654

Phone: (240) 429-0083

FAX: (614) 292-1272

E-mail:

Office Hours: Mondays Noon – 1:20 PM & Wednesdays & Fridays 9:00 – 11:00 AM and by appointment

Class Location:SB 230

Class Time:1:50 – 2:45 PM (M W & F)

On-Line Training:

PREREQUISITES

Students are expected to have access to a Windows-based laptop computer with high-speed internet access.

COURSE DESCRIPTION

This course is designed to familiarize students with the Six Sigma process improvement methodology and to provide them an opportunity to practice using Six Sigma Green Belt tools. A Six Sigma Green Belt is an individual who is skilled in applying basic and advanced process improvement and project management methods in order to complete projects that will result in significant, sustainable improvements within an organization. Originally developed by Motorola to improve quality in manufacturing processes, Six Sigma has been adopted by companies throughout the world to improve all types of processes.

When applied in business environments, Six Sigma programs have been used to dramatically increase an organization’s ability to improve quality and customer satisfaction while reducing overall costs. Companies such as AlliedSignal and General Electric have used Six Sigma to significantly increase productivity, operating income and cash flow.

In this course, students will gain an understanding of the strategy and deployment of Six Sigma Green belt methods. The classroom sessions will combine lectures with group discussions and hands-on exercises and student presentations.

To complement the Monday, Wednesday and Friday sessions, students will be required to complete online coursework at and other assignments during non-classroom hours.

COURSE FORMAT

Blended learning uses different venues, synchronous/asynchronous/classroom, to help improve the learner’s retention and provide a richer learning environment. This is accomplished by allowing the student to learn the cognitive skills online allowing the classroom to focus more on hands-on applications. A blended format will be employed for this course. The learner is required to cover the online material prior to the classroom instruction. The classroom instruction is designed to enhance, augment and/or provide a hands-on exercise of the online material.

REQUIRED COURSE MATERIALS

MoreSteam.com’s web-accessed Six Sigma training program will be used as the textbook for this course.

PERFORMANCE EVALUATION

Grading:

Quizzes1 50 pts 5%

Homework (4)2100 pts 10%

Midterm I (Define & Measure)175 pts17.5%

Midterm II (Define, Measure & Analyze)175 pts17.5%

Comprehensive Exam250 pts 25%

SPC Project 75 pts 7.5%

Capstone Project2175 pts 17.5%

60 Points for DOE

40 Points for Presentation

75 Points for Report

Additional assignments/quizzes may be added at the instructor’s discretion.

1. Students are expected to complete the Moresteam.com material and take the quiz in Carmen prior to the class session.

2. Peer Evaluations required on the first three homework’s and the capstone project

Examinations:

The three exams will constitute 60% of your final grade. Each exam will be multiple choice and some questions will require data analysis using MoreSteam.com’s EngineRoom, Minitab or StatTools—students’ discretion. The material could be based on anything covered in the lecture, MoreSteam.com, videos or guest/student presentations. You will be allowed access your handwritten notes for all exams and quizzes. You MUST have an average of 58% (348 points out of the 600 points) on the three tests to pass the course—no make-up exams, no exceptions.

Quizzes/Homework/Projects:

These three topics will constitute 40% of your grade.

The quizzes in MoreSteam.com are NOT graded; they are for your own clarification. The graded quizzes will be in Carmen and will expire. If you have not taken the quiz prior to the expiration date/time, you will receive a zero for that quiz. Likewise, homework and projects will be collected in a dropbox within Carmen. It too will have an expiration date/time. If you have not submitted your homework prior to that date/time, you will receive a zero for that assignment. I will NOT accept homework, projects or peer evaluations via email, slid underneath my door or handed to me in class.

Unless otherwise specified, all homework will be done in a Word document and must use Modern Language Association (MLA) formatting—only exception: MLA formatting indicates to “leave only one space after periods or other punctuation marks (unless otherwise instructed by your instructor).” I require two spaces at the end of a sentence in lieu of one space; it makes the report easier to read. There is a MLA sample paper in Carmen under Content, and you can use the following site for criteria:

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The proper formatting is 50% of your grade for the fourhomework assignments and the two reports. You can use any software to perform the statistical analysis or make figures. Cut and paste any analysis/image you wish to include in the word document. Homework does not require a cover page.

On the 11th and 13th of September, we will collect data in class for homework assignments 2 and 3 respectively. A critical part of the homework assignment is understanding the context in which the data were collected; without this understanding, the report is meaningless. Therefore, if you are not present for a class when the homework data are generated, you will receive a zero for that homework assignment.

In this course, a rubric will not be provided for the last threehomework’s but will be provided for the two projects and the first homework assignment. The reason for no rubric for the homework is twofold: 1.) This is a senior level class; shortly you will be working in industry. In the 34 years I worked in industry, I was given many tasks to complete and was not given a rubric. In industry, you will be assigned many tasks where you will need to determine, on your own, your client’s expectations and meet them. You will have questions when working on the homework. I provide you with unfettered access to me by providing my cell number. You can ask these questions in person or text me. 2.) In this course, we teach you to define your customer(s) and understand their expectations; by not providing a rubric, I want you to practice what we are teaching you.

The two projects, SPC and Capstone, are formal reports and require a cover page. When using a cover page, you do not need the required first four lines (your name, instructor’s name, course and date) on page one as you did for your homework as this information should be on the cover page.

No make-up, late or early exams will be given, except in the case of medical emergency. Business related absences are not excused. Students should make arrangements now to avoid time conflicts.

Classroom Performance

The value of the class discussions is directly related to the amount of quality student participation.

- evidence of careful preparation of the on-line course work

- clarity and conciseness of your comments and recommendations

This class is generally aided by the use of laptop computers. However, your participation is greatly reduced by non-related Internet websites during class. In a recent audit of my class, the auditors reported:

We observed the following behaviors: playing video games, shopping, checking and writing email, surfing the web, and surfing around in Carmen. We were surprised by the amount of non-class related technology access, especially given the complexity of the topic.

The computer is for access to MoreSteam.com files and taking notes. I will not limit the use of computers in the classroom due to the behaviors of a few; however, I receive many comments in my student evaluations about the difficulty of the course/exams. The behavior identified above will only exacerbate any difficulty passing this class.

Attendance will be taken from time-to-time at the instructor’s discretion. It will not reflect in the grade but will be used to determine any forthcoming consideration.

DISABILITY ACCOMMODATION

If you need an accommodation based on the impact of a disability, arrange an appointment with me as soon as possible. We need to discuss the course format and explore potential accommodations. I rely on the Office for Disability Services for assistance in verifying need and developing accommodation strategies. You should start the verification process as soon as possible.

ACADEMIC MISCONDUCT

Material submitted for course grade credit must be your own work. I will report any suspected case to the University Academic Misconduct Committee for investigation. Past cases have typically resulted in the assignment of grade of E for the course. Academic misconduct is a serious threat to the integrity and value of the Fisher College diploma. Such behavior is intolerable.

COURSE OUTLINE

Date / Six Sigma Phase / Class Preparation Material / Topics Covered
1. Wed., 23 Aug
SB 230 / -Course Overview
-Evolution of Quality
2. Fri., 25 Aug
SB 230 / Intro / Moresteam.com – Session 1 / -Introduction to Six Sigma
3. Mon., 28 Aug
SB 230 / DEFINE / Moresteam.com – Session 3 / - Project Charter
- Card drop demo
- Voice of the Customer
- Affinity Diagram
4. Wed., 30 Aug
SB 230 / DEFINE / Moresteam.com – Session 2 / - Kano Analysis
- CTQC’s
5. Fri., 1 Sep
SB 230 / DEFINE / Moresteam.com – Session 4 / - QDS (process mapping)
6. Wed., 6 Sep
SB 230 / MEASURE / Moresteam.com – Session 5 / - Intro to Measure
- Types of data
- 4 Scales of data
7. Fri., 8 Sep
SB 230 / MEASURE / Moresteam.com – Session 6 / - MSA
- Stability, Linearity, bias
8. Mon., 11 Sep
SB 230 / MEASURE / Moresteam.com – Session 6 / - Discrete GR&R
9. Wed., 13 Sep
SB 230 / MEASURE / Moresteam.com – Session 6 / - Continuous GR&R
10. Fri., 15 Sep
SB 230 / MEASURE / Moresteam.com – Session 6 / -Gage R&R Using Mintab/EngineRoom
Date / Six Sigma Phase / Class Preparation Material / Topics Covered
11. Mon., 18 Sep
SB 230 / MEASURE / Moresteam.com – Session 7 / - SPC
- SPC Project
12. Wed., 20 Sep
SB 230 / MEASURE / Moresteam.com – Session 7 / -Types of SPC charts
13. Fri., 22 Sep
SB 230 / DEFINE & MEASURE / Review for Define & Measure Test Preparation document / Session 1 – 7
14. Mon., 25 Sep
SB 219 / DEFINE & MEASURE / Test I: Moresteam.com, Sessions 1 – 7 / - Open handwritten notes
15. Wed., 27 Sep
SB 230 / ANALYZE / Moresteam.com – Session 8 / -Scatterplots
-Regression Analysis
- Cause & Effect
Fishbone
16. Fri., 29 Sep
SB 230 / ANALYZE / Moresteam.com – Session 9
Data collection / - Hypothesis Testing
17. Mon., 2 Oct
SB 230 / ANALYZE / Moresteam.com – Session 9 / - Hypothesis Testing, Data collection
17. Wed., 4 Oct
SB 230 / ANALYZE / Moresteam.com – Session 9 / - DOE
18. Fri., 6 Oct
SB 230 / ANALYZE / Review for Define, Measure & Analyze Test Preparation doc. / - Sessions 1 – 9
19. Mon., 9 Oct
SB 219 / DEFINE MEASUREANALYZE / Exam II: Moresteam.com - Sessions 1 & 9 / - Open handwritten notes
20. Wed, 11 Oct / No Class
21. Mon., 16 Oct
SB 230 / IMPROVE / Moresteam.com – Session 10 / Brainstorming
Multi-voting
Decision Analysis
Date / Six Sigma Phase / Class Preparation Material / Topics Covered
22. Wed., 18 Oct
SB 230 / IMPROVE / Moresteam.com – Session 10 / Videos
-Time
-5S
23. Fri., 20 Oct
SB 230 / CONTROL / Moresteam.com – Session 11 / FMEA
Control Plan
24. Mon, 23 Oct
SB 230 / DEFINE / Catapult Simulation
Session 1 - 4 / - Shoot for the cup
25. Wed., 25 Oct
SB 230 / DEFINE / Catapult Simulation
Sessions 1 - 4 / - Project Charter
26. Fri., 27 Oct
SB 230 / MEASURE / Catapult Simulation
Sessions 5 - 7 / - Fishbone
27. Mon, 30 Oct
SB 230 / MEASURE / Catapult Simulation
Sessions 5 - 7 / - Gage R&R
28. Wed, 1 Nov
SB 230 / MEASURE / Catapult Simulation
Sessions 5 - 7 / - Gage R&R
29. Fri., 3 Nov
SB 230 / MEASURE / Catapult Simulation
Sessions 5 - 7 / - Capability Analysis
30. Mon., 6 Nov
SB 230 / DEFINE & MEASURE / Catapult simulation
Sessions 1 – 7 / Presentations 1st half
31. Wed., 8 Nov
SB 230 / DEFINE & MEASURE / Catapult simulation
Sessions 1 – 7 / Presentations 2nd half
32. Mon., 13 Nov
SB 230 / ANALYZE / Catapult simulation
Sessions 8 & 9 / Root Cause Analysis
33. Wed., 15 Nov
SB 230 / ANALYZE / Catapult simulation
Sessions 8 & 9 / Hypothesis testing
34. Fri., 17 Nov
SB 230 / ANALYZE / Catapult simulation
Sessions 8 & 9 / Hypothesis testing
Date / Six Sigma Phase / Class Preparation Material / Topics Covered
35. Mon., 20 Nov
SB 230 / ANALYZE / Catapult simulation
Sessions 8 & 9 / Hypothesis testing
36. Mon., 27 Nov
SB 230 / ANALYZE / Catapult simulation
Sessions 8 & 9 / DOE Preparation
37. Wed. 29 Nov
SB 230 / ANALYZE / Catapult simulation
Sessions 8 & 9 / DOE
38. Fri., 1 Dec
SB 230 / IMPROVE & CONTROL / Catapult simulation
Sessions 10 & 11 / Solving coded equation & Control Plan
39. Mon., 4 Dec
SB 230 / DMAIC / Catapult simulation
Sessions 1 – 11 / Catapult Simulation DMAIC Report
40. Wed., 6 Dec
SB 230 / DMAIC / Review for FINAL EXAM / Catapult Simulation DMAIC Report Due today at 5 PM
41. Wed., 13 Dec
TBD / DMAIC / Exam III: Moresteam.com sessions 1 – 11
2:00 – 3:45 PM / Comprehensive exam
DMAIC

Due to unforeseen circumstances, this schedule may change slightly. Any changes will be communicated in class, and it is the responsibility of the student to track the changes expressed in class.

Peer Evaluation

Your name: ______

Scoring Criteria:

1 2345

Did Not Meet ExpectationsMet ExpectationsExceeded Expectations

Group Members (including yourself):

Quality of Quantity of Working Timeliness

Name Effort Effort Relationships

______

______

______

______

______

______

Comments (Please comment on any score 2 or lower):