Department of Manufacturing Systems Engineering and Management

MSE 618 – Six Sigma Quality Engineering Fall 2009 Class Number 14826 Room JD1563

Instructor Jay Hamade Department of Manufacturing Systems Engineering and Management Faculty Office: JD3310 Office Hours: Wednesdays 6-7 PM or by appointment Faculty E-mail: [email protected] MSEM Department Office: JD4510; (818) 677-2167 MSEM Department E-mail: [email protected]

1. Gitlow, Howard S. & Levine, David M. (2005). Six Sigma for Green Belts and Textbook Champions. New Jersey: 2005 Pearson Education, Inc. ISBN 0-13-117262-X 2. Eckes, George (2001). The Six Sigma Revolution. New York: John Wiley and Sons, Inc.

Course Lecture notes for some sessions will be available from the instructor. Packet

Course Prerequisite MSE 601 or Consent of Instructor. Description Six Sigma is a process that enables companies to increase profits dramatically by streamlining operations, improving quality, and eliminating defects or mistakes in everything a company does, from raw materials to finish goods. This class will discuss the evolution of continuous improvement methodologies: TQM, SPC, and Six Sigma. Comparison of product-related and process-related Six Sigma methodologies. The integration of operating philosophies, applied statistics, and project management to produce effective and efficient business process through Six Sigma deployment. The five phases of the Six Sigma methodology (Define, Measure, Improve, and Control) and how to manage improvement projects using Six Sigma tools. The application of Six Sigma tools using statistical and business software, Minitab, and MS Project. Advance topics in Six Sigma like Design Of Experiment (DOE) and Lean Six Sigma (LSS).

Course  Understand and describe the History of Continuous Improvement methodology Learning  State the Goal and Role of Continuous Improvement in Industry Objectives  Explain and apply the Six Sigma Quality Engineering Methodology  Gain Applied Quality Engineering Project Management Experience  Make effective Product and Process Decisions using Six Sigma Methodologies  Demonstrate relevant computing technologies applications

MSE618 (Six Sigma Quality Engineering) - Page 1 of 5 Course Proposed Plan

Note: Tentative schedule: dates/assignments/topics covered may change as deemed necessary.

Week 1 Introductions to the instructor, class members and the course 08/26/09 Lecture: Gitlow & Levine Part I- Six Sigma Basics Continuous Improvements in the Aerospace Industry

Week 2 Reading Assignment: Gitlow & Levine Part II – Six-Sigma Model: 09/02/09 - Macro Model of Six Sigma Management (pp. 45-59) Introduction to the Define Phase of the DMAIC Model

Week 3 Reading Assignment: Gitlow & Levine Part II – Six-Sigma Model: 09/09/09 - Define Phase of the DMAIC Model (pp. 62-98) Comprehensive Six Sigma Project: Teams and Projects will be selected

Week 4 Reading Assignment: Gitlow & Levine Part II- Six-Sigma Model: 09/16/09 - Measure Phase of the DMAIC Model (pp. 104-142) Comprehensive Project Team Presentation – Define phase

Week 5 Gitlow & Levine Part II- Measure Phase of the DMAIC Model 09/23/09 Introduction to Minitab Statistical Software Tool

Week 6 Homework Assignment #1 is due 09/30/09 Comprehensive Project Team Presentation- Measure phase Class exercises- Data mining using Minitab & Excel

Week 7 Reading Assignment: Gitlow & Levine Part II- Six-Sigma Model: 10/07/09 - Analyze Phase of the DMAIC Model (pp. 145-189) Minitab lecture and class exercises

Week 8 Homework Assignment # 2 is due 10/14/09 Gitlow & Levine Part II- Analyze Phase of the DMAIC Model

Week 9 Comprehensive Project Team Presentation- Analyze Phase 10/21/09 Team Presentation- The Six Sigma Revolution book review

Week 10 Homework Assignment #3 is due 10/28/09 Introduction to Lean Manufacturing Minitab lecture and class exercises

Week 11 Reading Assignment: Gitlow & Levine Part II- Six-Sigma Model:

MSE618 (Six Sigma Quality Engineering) - Page 2 of 5 11/04/09 - Improve Phase of the DMAIC Model (pp. 194-214) Minitab lecture and class exercises

Week 12 Veteran’s Day Holiday- No class 11/11/09

Week 13 Comprehensive Project Team Presentation- Improve Phase 11/18/09 Reading Assignment: Gitlow & Levine Part II- Control Phase (pp. 217-225) Minitab lecture and class exercises

Week 14 Gitlow & Levine Part II- Control Phase of the DMAIC Model (pp. 217-225) 11/25/09 Reading Assignment: Gitlow & Levine Part II- Minitab lecture and class exercises

Week 15 Comprehensive Project Team Presentation- Control Phase 12/02/09 Homework Assignment #4 is due

Week 16 Comprehensive Team Project Final Presentation- DMAIC 12/09/09 Course review for final exam

Week 17 Comprehensive Final Exam- DMAIC 12/16/09

PROJECT AND HOMEWORK ASSIGNMENT DESCRIPTIONS

Comprehensive Project: Six Sigma (DMAIC)

The comprehensive Six Sigma Project is a team-based project that spans the entire semester. The project evaluation will be based on five gate reviews for each Six Sigma phase. The gate review will consist of a 15-minute presentation by the team (5%). Each member of the group will also receive a score of a (5%) by other team members for attendance, participation, and effort. It is expected that the role of project manager be rotated among team members. A final report with lessons learned and the summary of all gate reviews is also required for (5%). The project evaluation is comprehensive. In other words, every gate review is required.

Homework Assignments

1. There will be 4 homework assignments. 2. Class members are responsible for material reading assignments and homework assignment. 3. Tardy submissions are unacceptable unless arranged in advanced. 4. Some homework assignments can be worked in a group of 4 to 5 students/group; one set

MSE618 (Six Sigma Quality Engineering) - Page 3 of 5 (the original) should be turned in per group; all students need to have a copy of the homework with them in class to be able to follow the solution 5. Homework assignments will be due at the beginning of the session (see assignments schedule above).

Book Review- The Six Sigma Revolution

Teams consist of 4 to 5 students/team will conduct a book review and present a summary of the Six Sigma Revolution to the class. Note: All team members are encouraged to participate in this class presentation.

STANDARD OPERATING PROCEDURES

1. Class members are encouraged to maintain personal and professional standards consistent with The Fundamental Principles of the Code of Ethics of the Accreditation Board for Engineering and Technology.

2. Withdrawing from (dropping) this course should be accomplished during the first two weeks of instruction. Please note that failure to officially drop any course results in a grade of U, which is the equivalent of an F for your transcript and grade point average.

3. It is a University requirement that all undergraduate and graduate students must pass the Writing Proficiency Examination (WPE) as part of earning their degree. Graduate students must pass the WPE before completing more than 12 units in their graduate program. Students who earned an undergraduate degree at CSUN in Spring 1982 or thereafter have already met the requirement. Delaying the completion of the WPE requirement can delay your graduation. For additional information, see FAQs at www.csun.edu/~msem, or contact your academic advisor.

4. It is a University requirement that all graduate students whose overall undergraduate degree grade point average was less than 3.0, and who have not taken the General Aptitude Test of the Graduate Record Examination (GRE), must take the test before completing more than 12 units in their graduate program. A delay in meeting the GRE requirement will delay your classification and can delay your graduation. Information on the test is available at www.gre.org or at FAQs at www.csun.edu/~msem, or by contacting your academic advisor.

5. The major of each student in this class will be verified using the University course roster. Students whose majors are not correct must submit a change of major within the first three weeks of the semester. Graduate students should submit a Change of Objective for Graduate Students to the MSEM Department Office. The form can be obtained from FAQs at www.csun.edu/~msem, or by contacting your academic advisor.

6. The classification status of each graduate student in this class will be verified using the University course roster. Conditionally classified graduate students who are eligible for classification must submit a Request for Classification during the first three weeks of the semester. Eligible students are in the correct major and in GRAD status, have met their

MSE618 (Six Sigma Quality Engineering) - Page 4 of 5 WPE and GRE requirements, and have a GPA of 3.0 or better. . For additional information, see FAQs at www.csun.edu/~msem, or contact your academic advisor.

7. Class members are to be considerate and respectful of their colleagues, particularly in regard to the project assignment, team effort and presentations. 8. Class members are responsible for material in reading assignments, CD companion, class presentations and group discussions.

9. Class members are expected to prepare and participate constructively in group discussions and team meetings.

10.All graduate students majoring in MSEM Department programs (i.e. Automation Engineering, Engineering Management, Materials Engineering) are encouraged to add their e-mail addresses to the Department listing. This listing is used for special notifications (e.g. course scheduling changes, academic advisement notices, social events, and emergencies). The list may be accessed at www.csun.edu/~msem/faqs.htm or by e-mailing a request to [email protected] to be added to the list.

COURSE EVALUATION STRUCTURE

Comprehensive Project: 35%  Gate review-DMAIC 5%  Project Participation 5%  Final Report 10% Book Review- Presentation Exams: 25%  Final Homework Assignments: 5%  Homework Assignment # 1 5%  Homework Assignment # 2 5%  Homework Assignment # 3 5%  Homework Assignment # 4

Letter-Grade Scale

A ≥ 90 88 ≤ A- < 90 85 ≤ B+ < 88 80 ≤ B < 85 78 ≤ B- < 80 75 ≤ C+ < 78 70 ≤ C < 75 68 ≤ C- < 70 60 ≤ D < 68 F < 60

Note: Plus/Minus Grading WILL BE USED for this course

MSE618 (Six Sigma Quality Engineering) - Page 5 of 5