WORK08010 2016 Work Placement Preparation and Six Sigma 1

General Details

Full Title

Work Placement Preparation and Six Sigma 1

Transcript Title

Work Place Prep and Six Sigma 1

Code

WORK08010

Attendance

N/A %

Subject Area

WORK - Work Placement

Department

MENG - Mech. and Electronic Eng.

Level

08 - NFQ Level 8

Credit

05 - 05 Credits

Duration

Semester

Fee

€

Start Term

2016 - Full Academic Year 2016-17

End Term

9999 - The End of Time

Author(s)

Donal Lyons, Brian Coll, David Mulligan, Mary Nolan, Michael Moffatt

Programme Membership

SG_EPREC_K08 201600 Bachelor of Engineering (Honours) in Precision Engineering & Design SG_EPREC_K08 201900 Bachelor of Engineering (Honours) in Precision Engineering & Design (Add-on)

Description

This Module will consist of two elements:

Part A: Work Placement Preparation
Part B: Six Sigma 1 – Introduction to Lean Six Sigma Quality

Part A: Work Placement Preparation:

This element of the module will involve preparation for the Work Placement modules and will address relevant industry standard and codes of practice. Students will identify gaps in personal knowledge and skills, devise personal career development plans and prepare for Continued Professional Development. Details regarding the learning outcomes, indicative syllabus and assessment strategies for this element of the module are described in Part A below:

Part B: Six Sigma 1 – Introduction to Lean Six Sigma Quality :

This element of the module will be delivered online and will provide learners with an understanding of the tools and techniques of quality used in manufacturing industry to achieve a six sigma quality environment. Details regarding the learning outcomes, indicative syllabus and assessment strategies for this element of the module are described in Part B below:

Learning Outcomes

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

Identify gaps in personal knowledge and devise a personalised career development plan.

Outline the role that professional engineers play in the context of organisational teams, reporting structures, management practices and leadership styles.

Interpret the requirements of various industry standards in precision engineering and manufacturing industry.

Generate engineering documentation that reflects best practice.

Describe why organisations use Six Sigma and the Design for Six Sigma (DFSS) and DMAIC improvement methodology

Define and describe Lean concepts and tools.

Define, select and use the seven quality tools for problems solving, prioritising problems and improving processes, e.g. Cause & Effect, Scatter Plots and Pareto charts.

Define, select and use the seven (new) management and planning tools. eg. Affinity diagrams, matrix diagrams and tree diagrams.

Generate FMEAs and distinguish between Design and Process FMEAs.

10.

Calculate process performance metrics such as DPU, FTY, DPMO and Cost of Poor Quality (COPQ).

11.

Collect and summarise data using surveys, descriptive and inferential statistics and graphical methods.

Teaching and Learning Strategies

Part A - Work Placement Preparation - 1 hour per week lecture

Part B - Six Sigma 1: Introduction to Lean Six Sigma Quality - 1 hour per week online lecture and 1.25 hours per week of directed learning.

Module Assessment Strategies

Part A - Work Placement Preparation - 40% of the Total Marks (divided equally between Continuous Assessment and Final Exam)

Part B - Six Sigma 1: Introduction to Lean Six Sigma Quality - 60% (divided equally between Continuous Assessment and Final Exam)

Repeat Assessments

Resubmission of failing elements of the assessment and/or repeat examination

Indicative Syllabus

Part A

Work Placement Preparation

Coordinator

Michael Moffatt

Department

Mech. and Electronic Eng.

Description

This module will involve preparation for the Work Placement modules and will address relevant industry standard and codes of practice. Students will identify gaps in personal knowledge and skills, devise personal career development plans and prepare for Continued Professional Development.

Learning Outcomes

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

1. Identify gaps in personal knowledge and devise a personalised career development plan.
2. Outline the role that professional engineers play in the context of organisational teams, reporting structures, management practices and leadership styles.
3. Interpret the requirements of various industry standards in precision engineering and manufacturing industry.
4. Generate engineering documentation that reflects best practice.

Teaching and Learning Strategies

Lecture 1 hour per week

Assessment Strategies

Continuous Assessment 50%

Final Examination 50%

Repeat Assessment Procedures

Repeat examination and/or repeat assignment(s)

Indicative Syllabus

Career Development:

Self-directed Continuing Professional Development. Case studies, consultations, coaching, mentoring and reflective supervision. Aptitude tests and psychometric tests. Lifelong learning. Learning environments and educational technologies. Personal resume, professional qualifications statement or curriculum vitae.

Role of Engineer:

Professional bodies. Ethical responsibilities. Social, environmental, sustainability and commercial considerations. Risk based thinking. Team roles and development. Team work, group dynamics and leadership styles. Reporting structures. Interactions between engineering and other disciplines. Respective functions of technicians, technologists and engineers. Legal requirement frameworks governing personnel, environment, health, safety and risk issues.

Industry Standards:

Codes of practice. Industry standards. Current good manufacturing practice. Medical device manufacturing. Automotive product manufacturing. ISO standards. Quality standards. CCE Marking. Machine Directive. Risk management. Health and safety framework.

Documentation:

Technical report writing, professional presentations. Literature search and review. Abstracts and executive summaries. Synthesising of work. Communication tools. Effective communication. Documentation control, preventative and corrective action. Examples of user requirement specifications, technical documentation requirements and validation requirement. Operating procedures.

CourseWork / Assessment Breakdown

CourseWork / Continuous Assessment

50 %

End of Semester / Year Formal Examination

50 %

Coursework Assessment Breakdown

Description	Outcome Assessed	% of Total	Assessment Week
Continuous Assessment	1,2,3,4	50	OnGoing

End Exam Assessment Breakdown

Description	Outcome Assessed	% of Total	Assessment Week
Final Exam	1,2,3,4	50	End of Semester

Full Time Mode Workload

Type	Location	Description	Hours	Frequency	Avg Wkly Wrkld
Lecture	Flat Classroom	Lecture	1	Weekly	1.00

Total Average Weekly Learner Workload 1.00 Hours

Module Book Resources

Christine Fanthome, 2004; Work Placements: A Survival Guide for Students (Palgrave Study Guides) Palgrave Macmillan ISBN‑10 1403934347, ISBN‑13 9781403934345.

Trevor M. Young, 2005; Technical Writing A‑Z: A Commonsense Guide to Engineering Reports and Theses ASME Press ISBN‑10 0791802361, ISBN‑13 9780791802366.

Part B

Introduction to Lean Six Sigma Quality

Coordinator

Brian Coll

Department

Mech. and Electronic Eng.

Description

Six Sigma 1 - Introduction to Lean Sigma Quality aims to provide learners with an understanding of the tools and techniques of quality that are used in the attainment of a six sigma quality environment. The principle goal of Six Sigma is to reduce variation in the process and improve quality. This module is also designed to meet the requirements of the Six Sigma Yellow belt award.

Through practical examples and exercises learners will becomes proficient in the use of the basic problem solving techniques used to monitor and control processes. Topics include: Six Sigma Quality, DMAIC process, Seven Traditional Tools of Quality, Qualitative Tools, Lean principles and Process Management.

As this is an online course, the majority of students are working in industry. Student blogs will be used to share best practices in Six Sigma across the class. Best practices will be generic use of the six sigma tools rather than any company specific information.

Learning Outcomes

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

1. Describe why organisations use Six Sigma and the Design for Six Sigma (DFSS) and DMAIC improvement methodology.
2. Define and describe Lean concepts and tools
3. Define, select and use the seven quality tools for problems solving, prioritising problems and improving processes, e.g. Cause & Effect, Scatter Plots and Pareto charts.
4. Define, select and use the seven (new) management and planning tools, e.g. Affinity diagrams, matrix diagrams and tree diagrams
5. Generate FMEAs and distinguish between Design and Process FMEAs.
6. Calculate process performance metrics such as DPU, FTY, DPMO and Cost of Poor Quality (COPQ).
7. Collect and summarise data using surveys, descriptive and inferential statistics and graphical methods.

Teaching and Learning Strategies

The online teaching and learning strategy will follow the guidelines as developed by Quality Matters: http://www.qmprogram.org/

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.

Assessment Strategies

Assessment will be through a series of continuous assessments, which will include Quiz's and assignment submissions via our online learning management system Moodle.

Repeat Assessment Procedures

Resubmission of failing elements of the assessments.

Assessment Facilities

Students will need access to a PC / Laptop and Minitab software for this course. Minitab software is available for rent at a discounted student rate for the duration of the semester.

Indicative Syllabus

Overview: Six Sigma and the Organisation

A. Six sigma and organisational goals

Value of six sigma

Recognize why organisations use six sigma, how they apply its philosophy and goals, and the origins of six sigma (Juran, Deming, Shewhart, etc.). Describe how process inputs, outputs, and feedback impact the larger organization.

Organisational drivers and metrics

Recognise key drivers for business (profit, market share, customer satisfaction, efficiency, product differentiation) and how key metrics and scorecards are developed and impact the entire organisation.

Organizational goals and six sigma projects

Describe the project selection process including knowing when to use six sigma improvement methodology (DMAIC) as opposed to other problem‑solving tools, and confirm that the project supports and is linked to organisational goals. Understand the roles and responsibilities of six sigma team members (i.e., individual team members, yellow belt, green belt, black belt, process owner, champion and sponsor.)

B. Lean principles in the organisation

Lean concepts and tools

Define and describe concepts such as value chain, flow, pull, perfection, visual management and tools commonly used to eliminate waste, including kaizen, 5S, error‑proofing, value‑stream mapping, standardised work and TPM.

Identify the difference between value‑added and non‑value‑added activities

Identify the seven wastes in terms of excess inventory, space, test inspection, rework, transportation, storage, and reducing cycle time to improve throughput.

Describe the Theory of constraints

C. Design for Six Sigma (DFSS) in the organisation

Quality function deployment (QFD)

Describe how QFD fits into the overall DFSS process.

Define and distinguish between design FMEA (DFMEA) and process (PFMEA) and interpret associated data.

Road maps for DFSS

Describe and distinguish between DMADV (define, measure, analyze, design, verify) and identify how it relates to DMAIC and how it helps close the loop on improving the end product/process during the design (DFSS) phase.

II. Six Sigma ‑ Define

A. Process Management for Projects

Process elements

Define and describe process components and boundaries. Recognise how processes cross various functional areas and the challenges that result for process improvement efforts.

Owners and stakeholders

Identify process owners, internal and external customers, and other stakeholders in a project.

Identify customers

Identify and classify internal and external customers as applicable to a particular project, and show how projects impact customers.

Collect customer data

Use various methods to collect customer feedback (e.g., surveys, focus groups, interviews, observation) and identify the key elements that make these tools effective. Review survey questions to eliminate bias, vagueness, etc.

Analyse customer data

Use graphical, statistical, and qualitative tools to analyse customer feedback.

Assist in translating customer feedback into project goals and objectives, including critical to quality (CTQ) attributes and requirements statements. Use voice of the customer analysis tools such as quality function deployment (QFD) to translate customer requirements into performance measures.

C. Management and planning tools

Define, select, and use the following quality tools:

Brainstorming and affinity diagrams, (5 Why ‑ 1 How analysis)
interrelationship diagraphs,
tree diagrams,
prioritisation matrices,
Force Field Analysis and matrix diagrams,
process decision program (PDPC) charts, and
activity network diagrams
Gantt Charts and Work Breakdown Structure (WBS)

D. Business results for projects

Process performance

Calculate process performance metrics such as defects per unit (DPU), rolled throughput yield (RTY), cost of poor quality (COPQ), defects per million opportunities (DPMO) sigma levels and process capability indices.

Track process performance measures to drive project decisions.

Failure mode and effects analysis (FMEA)

Define and describe failure mode and effects analysis (FMEA). Describe the purpose and use of scale criteria and calculate the risk priority number (RPN).

III. Six Sigma ‑ Measure

A. Process analysis and documentation

Process modeling

Develop and review process maps, written procedures, work instructions, flowcharts, etc.

Identify process input variables and process output variables. Use (SIPOC) (suppliers, inputs, process, outputs, and customers) to identify and define important elements of a process.

B. Collecting and summarising data

Types of data and measurement scales. Define and distinguish between qualitative and quantitative types of data.

Identify and classify continuous (variables) and discrete (attributes) data. Describe and define nominal, ordinal, interval, and ratio measurement scales.

Data collection methods

Define and apply methods for collecting data such as check sheets, coded data, etc.

Techniques for assuring data accuracy and integrity

Define and apply techniques such as random sampling, stratified sampling, sample homogeneity, etc.

Descriptive statistics

Define, compute, and interpret measures of dispersion (Standard deviation, range, variance) and central tendency (mean, median, mode), and construct and interpret frequency distributions and cumulative frequency distributions.

Graphical methods and charts.

Depict relationships by constructing, applying and interpreting diagrams and charts such as stem‑and‑leaf plots, box‑and‑whisker plots, run charts, scatter diagrams, correlation and regression Analysis and Pareto charts.

Depict distributions by constructing, applying and interpreting diagrams such as histograms. Describe how the Histogram shape (skewed and bimodal) can affect data interpretation.

Introduction to SPC and Control Charts

CourseWork / Assessment Breakdown

CourseWork / Continuous Assessment

50 %

End of Semester / Year Formal Examination

50 %

Coursework Assessment Breakdown

Description	Outcome Assessed	% of Total	Assessment Week
Moodle Online and Offline Assignments and Quiz submissions	1,2,3,4,5,6,7	50	OnGoing

End Exam Assessment Breakdown

Description	Outcome Assessed	% of Total	Assessment Week
Final Exam	1,2,3,4,5,6,7	50	End of Semester
Online Learning Mode Workload

Type	Location	Description	Hours	Frequency	Avg Wkly Wrkld
Online Lecture	Not Specified	Moodle	1	Weekly	1.00
Directed Learning	Distance Learning Suite	Theory	1.25	Weekly	1.25.00

Total Average Weekly Learner Workload 4.00 Hours

Full Time Mode Workload

Type	Location	Description	Hours	Frequency	Avg Wkly Wrkld
Lecture	Lecture Theatre	Lecture	4	Weekly	4.00

Total Average Weekly Learner Workload 4.00 Hours

Module Book Resources

Authors	Title	Publishers	Year
Paul A. Keller	Six Sigma Demystified 2nd edition ISBN:0071445447	McGraw‑Hill Professional	2011
Munro et al	The Certified Six Sigma Green Belt handbook	ASQ Quality Press	2015
Quentin Brook	Six Sigma and Minitab: a complete toolbox guide for all six sigma practitioners	OPEX Resources Ltd	2014

Module Other Resources

Listed on Moodle course page

Additional Information

Sample workshops for Fulltime students:

Workshop 1 ‑ Introduction to Lean Six Sigma

Workshop 2 ‑ Control Charts Simulation ‑ Red Bead Experiment

Workshop 3 ‑ Lean Simulation ‑ Plug Game

Each workshop will run for 4 hours.

Coursework & Assessment Breakdown

Coursework & Continuous Assessment

50 %

End of Semester / Year Formal Exam

50 %

Coursework Assessment

	Title	Type	Form	Percent	Week	Learning Outcomes Assessed
1	Assessment of Work Placement Preparation	Coursework Assessment	Assignment	20 %	OnGoing	1,2,3,4
2	Assessment of Six Sigma 1	Coursework Assessment	Assignment	30 %	OnGoing	5,6,7,8,9,10,11

End of Semester / Year Assessment

	Title	Type	Form	Percent	Week	Learning Outcomes Assessed
1	Examination of Work Placement Preparation	Final Exam	Closed Book Exam	20 %	End of Semester	1,2,3,4
2	Examination of Six Sigma 1	Final Exam	Closed Book Exam	30 %	End of Semester	5,6,7,8,9,10,11

Full Time Mode Workload

Type	Location	Description	Hours	Frequency	Avg Workload
Lecture	Flat Classroom	Work Placement Preparation	1	Weekly	1.00
Online Lecture	Online	Six Sigma 1	1	Weekly	1.00
Directed Learning	Online	Six Sigma 1 online assginments	1.25	Weekly	1.25

Total Full Time Average Weekly Learner Contact Time 3.25 Hours

Module Resources

Non ISBN Literary Resources

See Part A and Part B