Six Sigma

By Prof. Jitesh J Thakkar | IIT Kharagpur

Learners enrolled: 4432

The course on Six-Sigma will focus on detailed strategic and operational issues of process improvement and variation reduction. Six-sigma is a measure of quality that strives for near perfection. It is a disciplined, data-driven approach for eliminating defects (driving towards six standard deviations between the mean and the nearest specification limit) in any process-from manufacturing to transactional and from product to service.
A Six-sigma defect is anything outside of customer specifications. To be tagged Six Sigma, a process must not produce more than 3.4 defects per million opportunities.
Six-sigma employs a systematic approach of DMAIC (Define, Measure, Analyze, Improve and Control) for the process improvement. This course will provide a detailed understanding on various issues specific to each phase of DMAIC.
The course is designed with a practical orientation and includes cases, industry examples and MINITAB software applications.
The course is designed to satisfy the need of both industry professionals and University students.
The content is beneficial to both manufacturing and service industry.

INTENDED AUDIENCE : Mechanical Engineering, MBA, Industrial Engineering

PREREQUISITES : Statistics

INDUSTRY SUPPORT : Manufacturing and Service Industry

Summary

Course Status :	Completed
Course Type :	Elective
Duration :	12 weeks
Category :	Management Studies Operations
Credit Points :	3
Level :	Undergraduate/Postgraduate
Start Date :	18 Jan 2021
End Date :	09 Apr 2021
Enrollment Ends :	01 Feb 2021
Exam Date :	25 Apr 2021 IST

Note: This exam date is subjected to change based on seat availability. You can check final exam date on your hall ticket.

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Course layout

Week 1 : QUALITY: FUNDAMENTALS AND KEY CONCEPTS
Lecture 1: Brief overview of the course

Lecture 2: Quality concepts and definition

Lecture 3: History of continuous improvement

Lecture 4: Six Sigma Principles and Focus Areas (Part 1)

Lecture 5: Six Sigma Principles and Focus Areas (Part 2)

Lecture 6: Six Sigma Applications

Week 2 : QUALITY: FUNDAMENTALS AND KEY CONCEPTS
Lecture 7: Quality Management: Basics and Key Concepts

Lecture 8: Fundamentals of Total Quality Management

Lecture 9: Cost of quality

Lecture 10: Voice of customer

Lecture 11: Quality Function Deployment (QFD)

Lecture 12: Management and Planning Tools (Part 1)

Lecture 13: Management and Planning Tools (Part 2)

Week 3 : DEFINE
Lecture 14: Six Sigma Project Identification, Selection and Definition

Lecture 15: Project Charter and Monitoring

Lecture 16: Process characteristics and analysis

Lecture 17: Process Mapping: SIPOC

Week 4 : MEASURE
Lecture 18: Data Collection and Summarization (Part 1)

Lecture 19: Data Collection and Summarization (Part 2)

Lecture 20: Measurement systems: Fundamentals

Lecture 21: Measurement systems analysis: Gage R&R study

Lecture 22: Fundamentals of statistics

Lecture 23: Probability theory

Week 5 : MEASURE
Lecture 24: Process capability analysis: Key Concepts

Lecture 25: Process capability analysis: Measures and Indices

Lecture 26: Process capability analysis: Minitab Application

Lecture 27: Non-normal process capability analysis

Week 6 : ANALYZE
Lecture 28: Hypothesis testing: Fundamentals

Lecture 29: Hypothesis Testing: Single Population Test

Lecture 30: Hypothesis Testing: Two Population Test

Lecture 31: Hypothesis Testing: Two Population: Minitab Application

Lecture 32: Correlation and Regression Analysis

Lecture 33: Regression Analysis: Model Validation

Week 7 : ANALYZE
Lecture 34: One-Way ANOVA

Lecture 35: Two-Way ANOVA

Lecture 36: Multi-vari Analysis

Lecture 37: Failure Mode Effect Analysis (FMEA)

Week 8 : IMPROVE
Lecture 38: Introduction to Design of Experiment

Lecture 39: Randomized Block Design

Lecture 40: Randomized Block Design: Minitab Application

Lecture 41: Factorial Design

Lecture 42: Factorial Design: Minitab Application

Week 9 : IMPROVE
Lecture 43: Fractional Factorial Design

Lecture 44: Fractional Factorial Design: Minitab Application

Lecture 45: Taguchi Method: Key Concepts

Lecture 46: Taguchi Method: Illustrative Application

Week 10 : CONTROL
Lecture 47: Seven QC Tools

Lecture 48: Statistical Process Control: Key Concepts

Lecture 49: Statistical Process Control: Control Charts for Variables

Lecture 50: Operating Characteristic (OC) Curve for Variable Control charts

Lecture 51: Statistical Process Control: Control Charts for Attributes

Lecture 52: Operating Characteristic (OC) Curve for Attribute Control charts

Lecture 53: Statistical Process Control: Minitab Application

Week 11 : CONTROL
Lecture 54: Acceptance Sampling: Key Concepts

Lecture 55: Design of Acceptance Sampling Plans for Attributes (Part 1)

Lecture 56: Design of Acceptance Sampling Plans for Attributes (Part 2)

Lecture 57: Design of Acceptance Sampling Plans for Variables

Lecture 58: Acceptance Sampling: Minitab Application

Week 12 : SIX SIGMA IMPLEMENTATION CHALLENGES
Lecture 59: Design for Six Sigma (DFSS): DMADV, DMADOV

Lecture 60: Design for Six Sigma (DFSS): DFX

Lecture 61: Team Management

Lecture 62: Six Sigma: Case study

Lecture 63: Six Sigma: Summary of key concepts

Books and references

1. Roderick A. Munro and Govindarajan Ramu and Daniel J. Zrymiak, The certified six sigma Green Belt Handbook, ASQ Quality Press and Infotech Standards India Pvt. Ltd.

2. T. M. Kubiak and Donald W. Benbow, The Certified Six Sigma Black Belt Handbook, Pearson Publication.

3. Forrest W. Breyfogle III, Implementing Six Sigma, John Wiley & Sons, INC.

4. Evans, J R and W M Lindsay, An Introduction to Six Sigma and Process Improvement, CENGAGE Learning.

5. Howard S. Gitlow and David M. Levine, Six Sigma for Green Belts and Champions, Pearson Education, Inc.

6. Montgomery, D C. Design and Analysis of Experiments, Wiley.

7. Mitra, Amitava. Fundamentals of Quality Control and Improvement, Wiley India Pvt Ltd.

8. Montgomery, D C. Statistical Quality Control: A modern introduction, Wiley.

Instructor bio

Prof. Jitesh J Thakkar

IIT Kharagpur

Dr. Jitesh J. Thakkar is a Professor at National Rail and Transportation Institute (NRTI), Vadodara – India’s first University dedicated in the field of Rail and Transportation education. He has served as a faculty at Department of Industrial and Systems Engineering, IIT Kharagpur for 10 years. He has professional experience of more than 20 years. He holds a Ph.D in Supply Chain Management from IIT Delhi, M.Tech. in Industrial Engineering from IIT Delhi and Bachelors of Engineering in Mechanical Engineering conferred with Gold Medal from one of the oldest Government Engineering College - Birla Vishvakarma Mahavidyalaya Engineering College, Sardar Patel University. His areas of interests include Transportation Management, Logistics and Supply Chain Management, Project Management, Service Operations Management, Six Sigma, Lean Manufacturing, Optimization, Statistical Modeling and System Dynamics. He has supervised 14 Ph.D and 80 B.Tech./M.Tech. projects at IIT Kharagpur. He is a productive researcher with H-index 24 and 70 research papers published in SCI/SCOPUS listed journals. He has extensively published in the high impact factor international journals such as International Journal of Production Economics, Transportation Research (Part- E), International Journal of Production Research, Computers and Industrial Engineering, Production Planning and Control, Expert Systems with Applications, Journal of Cleaner Production. He has published two books – Structural Equation Modeling and Project Management with Springer. He has executed more than 5.0 crore rupees of research and consultancy projects. He has extended training/consulting to various organizations such as L&T, DRDO, Food Corporation of India, Neyveli Lignite Corporation, Tata Steel, Tata Hitachi, Essar Steel, Ordnance Factory, Lakshmi Machine Works Ltd., Godrej, Qatar Chemical. His online course on “Six Sigma” offered by NPTEL has been attended by more than 20,000 University students and Industry professionals in last five years. He has delivered more than 100 invited sessions at various reputed platforms. He has been invited as a faculty expert by IIT Kanpur, IIT Madras, IIM Indore, NITIE Mumbai, NIT Surat, NIT Trichy, IRMA, AMA, BCCI Kolkata, L&T-PMI.

Course certificate

The course is free to enroll and learn from. But if you want a certificate, you have to register and write the proctored exam conducted by us in person at any of the designated exam centres.
The exam is optional for a fee of Rs 1000/- (Rupees one thousand only).
Date and Time of Exams: 25 April 2021 Morning session 9am to 12 noon; Afternoon Session 2pm to 5pm.
Registration url: Announcements will be made when the registration form is open for registrations.
The online registration form has to be filled and the certification exam fee needs to be paid. More details will be made available when the exam registration form is published. If there are any changes, it will be mentioned then.
Please check the form for more details on the cities where the exams will be held, the conditions you agree to when you fill the form etc.

CRITERIA TO GET A CERTIFICATE

Average assignment score = 25% of average of best 8 assignments out of the total 12 assignments given in the course.
Exam score = 75% of the proctored certification exam score out of 100

Final score = Average assignment score + Exam score

YOU WILL BE ELIGIBLE FOR A CERTIFICATE ONLY IF AVERAGE ASSIGNMENT SCORE >=10/25 AND EXAM SCORE >= 30/75. If one of the 2 criteria is not met, you will not get the certificate even if the Final score >= 40/100.

Certificate will have your name, photograph and the score in the final exam with the breakup.It will have the logos of NPTEL and IIT Kharagpur .It will be e-verifiable at nptel.ac.in/noc.

Only the e-certificate will be made available. Hard copies will not be dispatched.

Once again, thanks for your interest in our online courses and certification. Happy learning.

- NPTEL team

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