IE 6610 INTRODUCTION TO 6-SIGMA

Spring Summer Semester 2014

Tue-Th, Manoogian 5:30-7:20PM

FAYSAL KHALAF, Ph.D.

Office Hr. Tue-Th: 4:45 – 5:30 PM – By Appointment
(313) 815-0265
email: aa3824@wayne.edu
“Improve quality, you automatically improve productivity. You capture the market with lower
price and better quality. You stay in business, and you provide jobs. (It's) so simple." { W.
Edwards Deming }

COURSE DESCRIPTION: The attraction of Six Sigma methodology is obvious —

designs that work, fewer defects and wastes in manufacturing, faster processes, lowered
production costs, and greater customer satisfaction. With these pluses, it’s no wonder the world’s
leading companies are adopting the Six Sigma approach to product development in ever-growing
numbers. Now here’s a comprehensive course that covers fundamental aspects of Six Sigma, the
Six Sigma process improvement, that is, Define-Measure-Analyze-Improve-Control (DMAIC)
principles and tools.
This course will provide:
• A Green Belt level training certificate for B grade and higher
• Prepare for ASQ (American Society for Quality)’s Certified Six Sigma Black Belt Exam

LEARNING OUTCOMES
This course intends to institutionalize importance of Quality and how it is and can be applicable
in every field. Students will learn 6-Sigma concept, method and tools and would be able to:
• Develop conceptual and practical understanding of what six sigma is, benefits/ requirements
and tools used
• Apply method into real world to deliver result; learn a systematic 1, 2, 3 method for
achieving world-class quality in product development and manufacturing
• Develop understanding of how statistical/graphical data analysis enables data driven decision
making
• Changes the way we think and approach problem solving
• Changes the way we examine and look at data
• Appreciate availability and use data analysis software
• Builds on existing student basic understanding of statistics and data representation
• Students should feel that they are learning new skills after each class
• Cover the body of knowledge for certified six sigma black belt
• Master the basic skills and knowledge base for green belts

Textbook: Open Source Six Sigma Black Belt Material

Select one option dependent on whether you prefer having a hardcopy or Powerpoint slides.
1. Electronic Slide version (Make sure to select Minitab option):
http://www.opensourcesixsigma.com/Black-Belt-Training-Materials-v11-p/tm-bb-11.htm
2. Hardcopy version (Select Minitab):
http://www.opensourcesixsigma.com/Black-Belt-Course-Manual-p/cm-bb-e3.htm

Grading policy:
Weekly short quizzes: 15%
Homework: 7.5%
Project 7.5%
Midterm: 35%
Final 35%

CLASS PROJECTS
The major project counts for 100 points and is a group project.

SCHEDULE OF TOPICS
Week 1 Define
• Understanding Six Sigma
• Six Sigma Fundamentals
2. Define
• Selecting Projects
• Elements of Waste
• Define - Wrap Up
• Intro to Measure
3. Measure
• Post Homework # 1
• Process Discovery
• Six Sigma Statistics
4. Measure
• Measurement System Analysis
• Post Homework # 2
5. Measure
• Process Capability
• Measure – Wrap Up
6. Measure
• Post Homework # 3
• Midterm Review
• Intro to Analyze
• "X" Sifting
• Midterm
7. Analyze
• Inferential Statistics
8. Analyze
• Hypothesis Testing
• Analyze Wrap Up
9. Improve
• Process Modeling – Regression
 • Project Due
10. Improve
• Post Homework # 4
• Experimental Methods
• Full/Fractional Factorial
• Improve Wrap Up
11. Control
• Capability Analysis
• Statistical Process Control
• Six Sigma Control Plans
• Project Presentation
• Post Homework # 5
12. Control
• Lean Controls
• DMAIC Wrap Up
• Final Exam Review
13. Final Exam