Polk State College
ETI 1622 – Concepts of Lean Manufacturing and Six Sigma
BCI:
Instructor:
Cell Phone:
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www.polk.edu/bci
Dr. Eric Roe
863-669-2838
[email protected]
(by appointment)
ASL143
Spring 2012; M 5:30-8:00pm
ASL 146
3 hours Lecture, 3 credits
Prerequisite: Completion of the Engineering Technology Program core requirements and/or the
permission of the Program Director.
COURSE DESCRIPTION:
This course provides an introduction to the fundamentals of Lean techniques, based on the
concepts in the Toyota Production System model of business function operating systems. A
comprehensive overview of the Lean and Six Sigma methodologies including the Define,
Measure, Analyze, Improve, and Control (DMAIC) process improvement paradigm will be
presented.
GRADING:
Class participation:
Quizzes:
Hwk/Team projects:
Mid-term:
Final:
20%
10%
25%
20%
25%
Grading Scale: A (90-100%); B (80-89%); C (70-79%); D (60-69%); F (0-59%)
Several team activities will take place during the course to get hands-on experience with some
of the concepts learned. Reports on the team activities including an executive summary, tools
used, data analysis, results and recommendations, where applicable, will be required. You will
be asked to turn in the report one week after the activity takes place. In certain portions of the
course, team activities may be replaced with homework problem sets. Those are to be turned in
one week after received. Early in the semester a Lean Six Sigma project is to be assigned so
that the tools learned in this class are applied. The project could be from your current job or a
case study. A presentation of the project will be required at the end of the semester and will
form part of the grade for the final exam. The final exam will be composed of the project report
grade and a written exam. Time will be set aside at the end of the semester so that you may
put the finishing touches on the project.
Quizzes are designed to take 15 minutes, but you will be given 30 minutes to complete.
Attendance Policy: You are expected to attend every class meeting. Please notify the
instructor if you plan to miss a class for any reason. Missed classes will have a direct bearing
on your class participation grade.
Work Missed: There may be instances where worked missed due to absences can not be
made up. Please make arrangements with the instructor prior to a known absence to discuss
possible make up work.
Withdrawal Deadline: March 23, 2012
ACADEMIC DISHONESTY:
Each student is responsible for his or her work. It is assumed that each student is honest and
will abide by this standard; however, in the event that there is an indication or suspicion of
cheating/plagiarism, the situation shall be dealt with in accordance with the published College
policy. Copies of this policy are available in the Student Services Office.
The instructor reserves the right to submit student assignments to a plagiarism detection
service.
COURSE OBJECTIVES:
Upon the successful completion of this course, students will be able to:
1. Understand the basic concepts of Lean, based on the Toyota production system
2. Define the tools supporting the Lean model
3. Understand the rollout process
4. Recognize areas of improvement and the correct Lean tools to utilize
5. Understand the Six Sigma process and its impact on quality, customer satisfaction and costs
6. Design, analyze and deliver peer-to-peer appraisals based on Lean Transformation
Leadership requirements
COURSE CONTENT:
 Lean overview
 7 Wastes
 5S
 Hands-on simulation
 Value Stream Mapping
 Standardized Work
 Built-in Quality
 Problem Solving
 Simulation
 Just-in-Time
 Kaizen
 Designing Appraisal Questionnaires
 Delivery Training
 Analyze Data
 Generate and Deliver the Feedback
 Establish growth Options
 Executive Summaries
TEXTBOOK AND OTHER REQUIREMENTS:
Bill Carreira, Bill Trudell, Lean Six Sigma That Works, Amacom,
2006, ISBN: 9780814473474
Date
1/9
1/16
Topic Covered
Introductions and overview of course
Chapter 1: Overview of Lean Six Sigma
Dr. King Holiday – College Closed
Assignments
Handouts
Problem Set 1
Read Chapter 2:
Customer Satisfaction
Chapter 3: Waste
1/23
1/30
Introduction and review of Lean Six Sigma project.
Report 1
Chapter 4: Value Added, Non-Value Added, Required
Value Added
Quiz 1
2/6
Chapter 5: Flow and Pull vs Push and Batch; Balance
Report 2
Quiz 2
2/13
Chapter 6: Velocity, throughput and Lead Time
Problem Set 2
Chapter 7: Cost and Profit Cash Flow
2/20
Review for Mid-Term
Problem Set 3
Mid-Term Exam
2/27
Chapter 8: The Basic Tools of Lean Six Sigma
3/5
Spring Break – College Closed
3/12
Chapter 9: Value Stream Mapping (Baselining)
Report 3
Report 4
Quiz 3
3/19
Chapter 10: Lean Engineering Analysis
Chapter 11: Set up Reduction
3/26
Chapter 12: 5s
Problem Set 4
Quiz 4
4/2
Chapter 13: Total Productive Maintenance (TPM)
4/9
Chapter 14: Practical Application of Lean Six Sigma:
Indirect Expenses
4/16
Chapter 18: The Psychology of Lean Six Sigma
4/23
Work on Lean Six Sigma Project
Final Project
4/30
Final Exam: Presentation of Lean Six Sigma Project and
written exam.
Final Project