ETI 1622 - Intro to Lean Six Sigma

Engineering and Building Arts Department

Credit(s): 3
Contact Hours: 47
Effective Term Spring 2021 (585)

Course Description

This course provides an introduction to the basic principles, and theories of lean manufacturing. Lean manufacturing involves identifying and eliminating non-value-adding activities in design, production, and supply chain management. The course introduces the concepts of Juran, Demming, Taylor, Ford, Shingo, and Ohno. The coverage also includes topics related to cost reduction, work-free manufacturing, continuous flow, Kaizen, the 5S’s, value stream mapping, modular manufacturing, and overall equipment effectiveness (OEE).

Learning Outcomes and Objectives

  1. Using the theories of lean manufacturing, the student will explain manufacturing improvement by:
    1. defining the terms associated with the processes of lean manufacturing.
    2. describing the three levels of improvement.
    3. defining and describing the three classes of equipment.
    4. describing chronic and sporadic equipment failure and how it applies to Takt Time and Just-in-Time models.
    5. defining the lead-time activities using value-added and non-value added ratios.
    6. defining overall equipment effectiveness (OEE) and its use in analyzing process performance.
  2. The student will prepare a value stream map by:
    1. defining the terms used in value stream mapping.
    2. identifying and describing the steps used in value stream mapping.
    3. applying the processes in a current value steam map.
    4. describing supply chain management.
    5. describing and using the Kaizen approach.
  3. The student will analyze just-in-time procedures by:
    1. describing the use of reduction charts.
    2. describing the use of Takt times.
    3. identifying and describing standard work for three production levels.
    4. describing standard work-in-process (WIP) in a workplace organization.
    5. determining the finished goods inventory (FGI).
    6. identifying inventory flow for a product activity.
    7. describing a cell to be used in a modular manufacturing flow.
  4. The student will describe continual improvement by:
    1. listing and discussing each step for continual improvement.
    2. outlining the process platform model during continual improvement.
    3. creating and analyzing fishbone diagrams.
    4. explaining the necessary actions for implementing corrective action.
    5. creating and analyzing Pareto charts to prioritize problems.
    6. defining continual improvement.
    7. discussing the use of the 5S’s, (sort, set in order, shine, standardize, sustain).
  5. The student will demonstrate a system of waste–free manufacturing by:
    1. defining the terms associated with waste-free manufacturing.
    2. identifying the 8 forms of waste: Defects; Excess Processing; Overproduction; Waiting; Inventory; Transportation; Motion; Un-utilized Talent.
    3. describing the four drivers of waste-free manufacturing and in the order of importance.
    4. describing the changes necessary in implementing waste-free manufacturing in a lean environment.
  6. The student will explain Lean-Six Sigma Enterprise by:
    1. describing the history and concepts related to Deming’s 14 Points and Crosby’s 4 Absolutes of Quality.
    2. examining the Malcolm Baldrige Criteria.
    3. describing the Toyota Production System.
  7. The student will describe the implementation of Lean-Six Sigma by:
    1. discussing enterprise assessment methods.
    2. developing the techniques to manage change.
    3. outlining the 10 step implementation plan.

Criteria Performance Standard

Upon successful completion of the course the student will, with a minimum of 70% accuracy, demonstrate mastery of each of the above stated objectives through classroom measures developed by individual course instructors.

History of Changes

C&I 6/25/02, BOT 7/29/02, Effective yrtr 20021. Number assigned effective 20032.(PS term 0330) effective 20032. 3 Year Review 2007. C&I Approval: 11/11/2003, BOT Approval: 12/16/2003, Effective Term: Spring 2004 (330).
C&I Approval: , BOT Approval: , Effective Term: Spring 2021 (585)

Related Programs

  1. Applied Engineering Technology (ENG-AS) (670) (Active)
  2. ASQ Certified Six Sigma Green Belt (to BIOT-AS) (SIG6IC-AR) (615) (Active)
  3. ASQ Certified Six Sigma Green Belt (to BMET-AS) (SIG5IC-AR) (615) (Active)
  4. ASQ Certified Six Sigma Green Belt (to ENG-AS) (SIG1IC-AR) (615) (Active)
  5. ASQ Certified Six Sigma Green Belt (to LEAN-CT) (SIG2IC-AR) (615) (Active)
  6. ASQ Certified Six Sigma Green Belt (to MDDM-CT) (SIG7IC-AR) (615) (Active)
  7. ASQ Certified Six Sigma Green Belt (to PROSYS-AS) (SIG8IC-AR) (615) (Active)
  8. ASQ Certified Six Sigma Green Belt (to SUSMGT-BAS) (SIG3IC-AR) (615) (Active)
  9. Biomedical Engineering Technology (BMET-AS) (640) (Active)
  10. Biotechnology Laboratory Technology (BIOT-AS) (640) (Active)
  11. Biotechnology Laboratory Technology (BIOT-AS) (635) (Draft)
  12. Council for Six Sigma Certification (CSSC) Six Sigma Green Belt (to BIOT-AS) (SSGB2IC-AR) (645) (Active)
  13. Council for Six Sigma Certification (CSSC) Six Sigma Green Belt (to BMET-AS) (SSGB6IC-AR) (645) (Active)
  14. Council for Six Sigma Certification (CSSC) Six Sigma Green Belt (to ENG-AS) (SSGB1IC-AR) (645) (Active)
  15. Council for Six Sigma Certification (CSSC) Six Sigma Green Belt (to MDDM-CT) (SSGB4IC-AR) (645) (Active)
  16. Council for Six Sigma Certification (CSSC) Six Sigma Green Belt (to SUSMGT-BAS) (SSGB3IC-AR) (645) (Active)
  17. Council for Six Sigma Certification (CSSC) Six Sigma Yellow Belt (to BIOT-AS) (SSYB2IC-AR) (645) (Active)
  18. Council for Six Sigma Certification (CSSC) Six Sigma Yellow Belt (to BMET-AS) (SSYB7IC-AR) (645) (Active)
  19. Council for Six Sigma Certification (CSSC) Six Sigma Yellow Belt (to ENG-AS) (SSYB5IC-AR) (645) (Active)
  20. Council for Six Sigma Certification (CSSC) Six Sigma Yellow Belt (to LEAN-CT) (SSYB6IC-AR) (645) (Active)
  21. Council for Six Sigma Certification (CSSC) Six Sigma Yellow Belt (to MDDM-CT) (SSYB1IC-AR) (645) (Active)
  22. Council for Six Sigma Certification (CSSC) Six Sigma Yellow Belt (to SUSMGT-BAS) (SSYB3IC-AR) (645) (Active)
  23. Lean Six-Sigma Green Belt (LEAN-CT) (610) (Active)
  24. Medical Device Design and Manufacturing (MDDM-CT) (580) (Active)
  25. Production Systems Management (PROSYS-AS) (645) (Active)
  26. Sustainability Management (SUSMGT-BAS) (640) (Active)
  27. Sustainability Management (SUSMGT-TR) (670) (Active)