CME347 LEAN MANUFACTURING

UNIT I BASICS OF 6 SIGMA

Introduction to 6 Sigma, basic tools of six sigma like problem solving approach, standard
deviation, normal distribution, various sigma levels with some examples, value for the enterprise,
Variation, and sources of variation, Mean and moving the mean, Various quality costs, cost of
poor quality.

UNIT II INTRODUCTION TO LEAN MANUFACTURING TOOLS

Process Capability Indices, Cause and Effect diagram, Control Charts, Introduction to FMEA,
APQP, PPAP. 3 foundational 6 Sigma methodologies: DMAIC, DMEDI, and Process
Management DMEDI for process creation, DMAIC for process improvement and PDCA for
sustaining improvements.

UNIT III DEEPER UNDERSTADING METHODOLOGIES

What is a process, Why Process management, Keys to process management, Difference between
process management and 6 Sigma, Introduction to Deming cycle, PDCA, DMAIC and
continuous improvement, DMEDI for creation process, DMAIC Vs DMEDI with examples,
Introduction to Toyota Production System, Six Sigma and Production System integration.

UNIT IV LEAN ELEMENTS

Introduction to Lean Concepts like In-Built Quality, Concept of Right Part at the Right Time,
Lead Time reduction, Optimum utilization of Capital, Optimum utilization of People.
Understanding the Zero-defect concept and Metrics, Focus on Human Resources, Quality,
Delivery, Cost. Building Zero defect capabilities, Cultural and Organizational aspects

UNIT V IMPLEMENTATION AND CHALLENGES

Implementing Checks and Balances in the process, Robust Information Systems, Dashboard,
follow up and robust corrective and preventive mechanism. Concept of Audits, and continuous
improvement from gap analysis, risk assessments etc.
TEXT BOOKS:
1. Quality Planning and Analysis- JM Juran& FM Gryna. Tata Mc Graw Hill
2. Lean Manufacturing: Principles to Practice by Akhilesh N. Singh, Bibliophile SouthAsia
3. The Toyota Way: 14 Management Principles
4. Gemba Kaizen: A Commonsense Approach to a Continuous Improvement Strategy,Masaki
Imai

REFERENCES:
1. Quality Council of India https://qcin.org/ & its library. https://qcin.org/nbqp/knowledge_bank/
2. International Society of Six Sigma Professionals: https://isssp.org/about-us/
3. NPTEL / SWAYAM: https://nptel.ac.in/courses/110105123 : Six Sigma, Prof. Jitesh J
Thakkar, IIT Kharagpur, Certification course. (Self- Learning).
4. Older / Previous editions of AIAG manuals on APQP, FMEA and PPAP. These are great
sources of information on Quality Planning and has basics of Project Management and required
skills.
5. Quality Management for Organizations Using Lean Six Sigma Techniques- Erick C Jones