PROJ07036 2019 Project Six Sigma 3

General Details

Full Title
Project Six Sigma 3
Transcript Title
Project Six Sigma 3
N/A %
Subject Area
PROJ - Project
MENG - Mech. and Electronic Eng.
07 - NFQ Level 7
05 - 05 Credits
Start Term
2019 - Full Academic Year 2019-20
End Term
9999 - The End of Time
Brian Coll
Programme Membership
SG_EMANM_J07 201900 Bachelor of Engineering in Manufacturing Management (Add-on) SG_ELSIG_S07 201900 Certificate in Lean Sigma Quality

The project aims to provide students with the opportunity to apply and integrate the skills and knowledge they have gained on the programme.

For students in employment, the project should address a substantive issue in the workplace. The project will test the student’s ability to define a real-life problem of concern to the organisation, design a strategy for addressing the problem, gather data, formulate and evaluate options and make recommendations. The project must follow the DMAIC problem-solving methodology using Lean and/or Six Sigma tools. 

For students not in employment and unable to complete a work-based project, then a simulated Lean Six Sigma project option may be undertaken. This will consist of reviewing six sigma case studies, analysing the data and using the appropriate Six Sigma tools and Minitab statistical software to identify the solutions to the problem.

A mentor will be assigned to each project, which may be individual or in some cases group projects. The mentor will act as a guide in agreeing the relevance, and scope of the project and monitor the progress on a regular basis. There will be regular contact between the student and their mentor as the project progresses throughout the semester. Updates will be sent to the mentor on an agreed basis.

Learning Outcomes

On completion of this module the learner will/should be able to;


Identify a problem which needs to be addressed of importance to the organisation.


Utilise an appropriate structured approach to manage the project with realistic, interim and overall project objectives.


Identify and use the appropriate Lean Six Sigma tools to address the problem and implement the required solution(s).


Present project results with Executive Summary, Conclusions and Recommendations and justify the approach that was taken and the results achieved.

Teaching and Learning Strategies

The online teaching and learning strategy will follow the guidelines as developed by Quality Matters:

Unique to the Quality Matters Rubric is the concept of alignment. This occurs when critical course components - Learning Objectives (2), Assessment and Measurement (3), Instructional Materials (4), Learner Interaction and Engagement (5), and Course Technology (6) - work together to ensure students achieve desired learning outcomes.

Module Assessment Strategies

The Project will be assessed by the student preparing interim and final written reports along with a presentation by the student. 

Project Type A: Six Sigma DMAIC

The Interim Report and Final Report are to be prepared in a structured format using Microsoft Word. The Final report should be at least 3000 words (10 - 12 pages) and contain the following major sections.

  • Executive Summary
  • Background & Objectives
  • Method (DMAIC)
  • Results
  • Conclusions & Recommendations

The Interim Report should address the 'Background & Objectives' and the 'Method' you plan to utilise to undertake your project.

Six Sigma Projects will be assessed taking into consideration the following:

1. Report Structure & Format

  • How clear were the aims and objectives?

  • Is the report well structured with logical flow and

  • Was supporting data available

  • Good use of charts and graphs

2. Students contribution

  • Individual Vs Team contribution

  • How critical was the student to the success of the overall project?

3. Problem-solving methodology used

  • Was the methodology appropriate to this project?

  • How many tools were used? - Six Sigma, Lean, Project Management, etc.

  • Should additional tools have been chosen?

4. Value to the company

  • Did the project meet its goals?

  • What metrics were improved?

  • How much money, time was saved, quality improved?

5. Level of innovation and technical difficulty

  • How innovative were the solutions proposed?

  • How technically difficult was the project?

  • Was the project complex, cross-functional?

Project Type B: Simulated Project

The student will prepare a Report/Presentation on each of the simulated projects. The report will contain the following major elements.

  • Executive Summary
  • Background of the Problem
  • Analysis of the Problem
  • Statistical analysis of the data collected
  • Conclusions and Recommendations
  • Appendices

Repeat Assessments

Repeat Assessments

Indicative Syllabus

Syllabus Content

  • The student should bring the learning from the subjects covered in the course to conceive, define and agree a project which is relevant to the students course of study.
  • Various types of projects may be undertaken depending on whether the student is full time or part time and their course of study.  Examples of these are as follows:

Project Type A: Six Sigma DMAIC

The Six Sigma project will be undertaken by the student and should address a substantive issue in the workplace. The project will test the student's ability to define a real-life problem of concern to the organisation, design a strategy for addressing the problem, gather data, formulate and evaluate options and make recommendations. The project should follow the Six Sigma DMAIC methodology. While it is recommended that the problem is addressed as part of a cross-functional team, it is important that the student makes a significant contribution to the success of the project. A financial saving must be identified. The Green belt is normally expected to contribute annualised savings from €10,000 - €20,000. The amount of savings will depend on the size of the company, sales revenue, number of employees and opportunities for improvements.

The Six Sigma project will also cover the following areas:

1. Project management basics

•· Project charter and problem statement

•· Define and describe elements of a project charter and develop a problem statement, including baseline and improvement goals.

•· Project scope

•· Assist with the development of project definition/scope using Pareto charts, process maps, etc.

•· Assist with the development of primary and consequential metrics (e.g., quality, cycle time, cost) and establish key project metrics that relate to the voice of the customer.

•·  Use project tools such as Gantt charts, critical path method (CPM), and program evaluation and review technique (PERT) charts, etc.

•· Provide input and select the proper vehicle for presenting project documentation (e.g., spreadsheet output, storyboards, etc.) at phase reviews, management reviews and other presentations.

•· Describe the purpose and benefit of project risk analysis, including resources, financials, impact on customers and other stakeholders, etc.

  • Describe the objectives achieved and apply the lessons learned to identify additional opportunities.

 2. Team dynamics and performance

•·  Define and describe the stages of team evolution, including forming, storming, norming, performing, adjourning, and recognition. Identify and help resolve negative dynamics such as overbearing, dominant, or reluctant participants, the unquestioned acceptance of opinions as facts, groupthink, feuding, floundering, the rush to accomplishment, attribution, discounts, plops, digressions, tangents,

•· Describe and define the roles and responsibilities of participants on six sigma and other teams, including black belt, master black belt, green belt, champion, executive, coach, facilitator, team member, sponsor, process owner, etc.

•· Define and apply team tools such as brainstorming, nominal group technique, multi-voting, etc.

•· Use effective and appropriate communication techniques for different situations to overcome barriers to project success.

Project Type B: Simulated Six Sigma Project

Where the student is unable to complete a project in the workplace, a simulated Six Sigma project may be undertaken by agreement with the lecturer.  The simulated project will consist of a number of six sigma case studies.  The student will be required to analyse the data from the case study using Minitab software and other Lean and Six Sigma statistical tools.  They will then present on their analysis along with conclusions and recommendations.

Coursework & Assessment Breakdown

Coursework & Continuous Assessment
100 %

Coursework Assessment

Title Type Form Percent Week Learning Outcomes Assessed
1 Project Proposal Project Written Report/Essay 15 % Start of Semester 1
2 Interim Report Project Project 20 % Any 2,3,4
3 Final Report and Presentation Project Project 65 % End of Term 4

Online Learning Mode Workload

Type Location Description Hours Frequency Avg Workload
Online Lecture Online Theory 2 Fortnightly 1.00
Tutorial Online Mentoring 3 Weekly 3.00
Independent Learning Online Project 4 Weekly 4.00
Total Online Learning Average Weekly Learner Contact Time 4.00 Hours

Required & Recommended Book List

Required Reading
2017 Lean Six Sigma and Minitab (5th Edition) OPEX Resources

Module Resources

Non ISBN Literary Resources

Recommended Reading 





  Writing Winning Reports And Essays

Janeczko, Paul B.


New York : Scholastic Reference.


 Project Management: The Managerial Process

Larson, Erik W.


McGraw-Hill Education


 The Six Sigma Handbook

 Thomas Pyzdek


 McGraw-Hill Education



 Six Sigma Demystified 2nd Edition ISBN:0071445447

Paul A. Keller


McGraw-Hill Professional



Journal Resources

Listed on Moodle course page

URL Resources

Listed on Moodle course page

Other Resources

Listed on Moodle course page

Additional Information

Listed on Moodle course page