BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE, PILANI

WORK INTEGRATED LEARNING PROGRAMMES

Digital Learning

Course Title Six Sigma

Course No(s) MM* ZG539
Credit Units 4
Credit Model 1-1-2
(32 Hours of Class-room Instruction + 32 Hours of Case-studies/Tutorials +
64 Hours of Student Preparation)
Instructor-In-Charge

Course Description:
History of Six Sigma, Implementing Six Sigma, Becoming a Customer and Market-Driven
Enterprise, Customer Expectations and Needs, Linking Six Sigma Projects to Strategies, Attributes
of Good Metrics, Using resources wisely, Project Management Using the DMAIC and DMADV
Models, The Define Phase, The Measure Phase, Measurement System Analysis, Analyzing Data:
Value Streams and Dealing with Variations, Designing Experiments, The Improve Phase, The
Control Phase.

COURSE OBJECTIVES

To orient successful professionals on a structured approach and an appreciative

CO1
mind set of practicing continuous improvement

To Familiarize the participants with the Toolsets and Technology – Getting

CO2 knowledge of the tools, models and frameworks that are used to practice six
sigma.

Engineering high performance – Applying the mindset and Toolset to feel the
CO3 change and achieve organizational high performance

Culture of Excellence Demonstrating Personal Excellence and catalyzing change

CO4 that builds a Culture that is essential to sustain the six sigma culture

CO5

LEARNING OUTCOMES
LO1 Participants will gain a solid knowledge of the theory, composition, and
implementation of Six Sigma initiative.

LO2 Participants will become proficient in all of the analytical tools necessary to
define, measure, analyze, improve, and control Six Sigma improvement projects

LO3 Participants will learn team leadership and project management skills

LO4 Participants will master the skills necessary to lead a complex process
improvement project that produces bottom- line results.

Text Book(s):
T1 Thomas Pyzdek & Paul Keller. “Six Sigma Handbook”,3rd Edition,2010
T2 David H Treicheler “The six sigma path to leadership”
T3 James P Womack & Daniel T Jones “Lean Solutions”
T4
T5

Reference Book(s) & other resources:

R1
R2

Content Structure:

Session 1: Introduction to Six Sigma

Topic No. Topic Title Reference
1.1 History of six sigma
1.2 Importance of six sigma and its philosophy
T1, Ch1
1.3 Six sigma philosophy
1.4 Managing change

Session 2: Implementing Six Sigma

 Topic No. Topic Title Reference
2.1 Time table and Infrastructure
2.2 Integrating six sigma
2.3 Supply chain Management (SCM) and deployment of six sigma to
T1, Ch1
SCM
2.4 Communications and Awareness

Session 3: Recognizing Opportunity in Six Sigma

Topic No. Topic Title Reference
3.1 Becoming a customer and market driven enterprise
3.2 Customer expectation and needs
T1, Ch2
3.3 Linking six sigma to project strategies

Session 4: Data Driven Management

Topic No. Topic Title Reference
4.1 Attributes of good matrices
4.2 Balance Scorecard
T1, Ch3
4.3 COPQ
4.4 Benchmarking

Session 5: Resource Maximization:

Topic No. Topic Title Reference
5.1 Selecting the right project
5.2 Ongoing Management support T1, Ch4
5.3 Tracking project result

Session 6: Project Management using DMAIC and DMADV

Topic No. Topic Title Reference
6.1 DMAIC and DMADV deployment models
T1, Ch5
6.2 Six sigma teams

Session 7: The Define Phase

Topic No. Topic Title Reference
7.1 Project Charters
7.2 Project Decompositions
T1, Ch6
7.3 Project Deliverables & Scheduling
7.4 Process maps

Session 8: The Measure Phase

Topic No. Topic Title Reference
8.1 Process and Matrix definition
8.2 Process baseline estimates T1, Ch7
 8.3 Capability analysis

Session 9: Measurement System Evaluation

Topic No. Topic Title Reference
9.1 Measurement System Discrimination
9.2 Stability, Bias & Repeatability
T1, Ch9
9.3 Part to Part variation
9.4 Linearity
9.5 Attribute measurement error analysis

Session 10: Analyze Phase : Value Stream Analysis

Topic No. Topic Title Reference
10.1 Value stream mapping
10.2 Spaghetti charts
T1, Ch10
10.3 Case study

Session 11: Analyze Phase : Analysing Sources of Variation and Analysis

Topic No. Topic Title Reference
11.1 Analysing sources of variation
11.2 Hypothesis testing
T1, Ch10
11.3 Regression and Correlation analysis

Session 12: Analyze Phase: Designing Experiments

Topic No. Topic Title Reference
12.1 Terminology
12.2 Types of design and characteristics
T1, Ch10
12.3 ANOVA
12.4 Analysis of Categorical data

Session 13: The Improve Phase: Decision and Empirical models

Topic No. Topic Title Reference
13.1 Customer demands to make design and improvement decisions
13.2 Lean techniques for optimizing the flow
T1, Ch11
13.3 Using Empirical model building to optimize

Session 14: The Improve Phase: Risk Assessment and Optimization

Topic No. Topic Title Reference
14.1 Design review
14.2 FTA, Safety Analysis, FMEA
T1, Ch11
14.3 Optimization using simulation
Session 15: The Control Phase
Topic No. Topic Title Reference
15.1 Validating new process or product design
15.2 Process control plan
T1, Ch12
15.3 Selecting process control elements
15.4 Process Audit

Session 16: Review Session

Topic No. Topic Title Reference
16 Revision of all topics

Project Activity/ Experiential Lab using Minitab:

1 Descriptive analysis
2 Developing various graph, Quality tools and analysis
3 Control Chart analysis
4 Regression analysis, DOE, ANOVA
5 Process capability
6 Gage R & R analysis

Evaluation Scheme:

Legend: EC = Evaluation Component; AN = After Noon Session; FN = Fore Noon Session

No Name Type Duration Weight Day, Date, Session, Time
EC1 Quiz 10%
Assignments /
EC-1 20%
Experiential lab
EC-2 Mid-Semester Test Closed Book 2 hours 30%
EC-3 Comprehensive Exam Open Book 3 hours 40%
Elearn portal: https://elearn.bits-pilani.ac.in.
Students are expected to visit the Elearn portal on a regular basis and stay up to date with the latest
announcements and deadlines.
Contact sessions: Students should attend the online contact sessions as per the schedule provided on the
Elearn portal.
Evaluation Guidelines:
1. EC-1 consists of Quizzes, assignments, project
2. For Closed Book tests: No books or reference material of any kind will be permitted.
3. For Open Book exams: Use of books and any printed / written reference material (filed or bound) is
permitted. However, loose sheets of paper will not be allowed. Use of calculators is permitted in all
exams. Laptops/Mobiles of any kind are not allowed. Exchange of any material is not allowed.
4. If a student is unable to appear for the Regular Test/Exam due to genuine exigencies, the student
should follow the procedure to apply for the Make-Up Test/Exam which will be made available on
 the Elearn portal. The Make-Up Test/Exam will be conducted only at selected exam centres on the
dates to be announced later.
5. Syllabus for Mid-Semester Test (Closed Book): Contact Hours 1 to 8
6. Syllabus for Comprehensive Exam (Open Book): Contact Hours 1 to 16
It shall be the responsibility of the individual student to be regular in maintaining the self-study schedule
as given in the course handout, attend the online lectures, and take all the prescribed evaluation
components such as Quizzes, Assignments, Project, Mid-Semester Test and Comprehensive Examination
according to the evaluation scheme provided in the handout.

Instructor-in-charge
(MM *ZG539)