Improving the quality of business processes - Lean 6 Sigma

• Biomedical Engineering, Semester 3, position 5
• Industry Engineering, Semester 3, position 5
• Inženjerska grafika i mehatronika, Semester 3, position 5

The aim of the course is to acquaint students with modern approaches and methods for improving the quality of production processes, using Lean management approaches and the Six Sigma methodology, and students to be able to apply the aforementioned tools.

Upon completion of the course, students are able to: 1. Understand the concept of Lean - resource-saving production. 2. Understand Lean tools and capacity utilization, including Kaizen and Gemba procedures. 3. They understand and apply quality control methods in production, including the Six Sigma methodology. 4. They understand the basics of integrating the Lean concept and the Six Sigma methodology. 5. They master the methodology of experiment design, which includes the method of setting up, conducting the experiment and realizing the analysis and post-analysis of the modern approach of statistical design of experiments, including the interpretation of regression and correlation analysis.

1. Basics of the Lean resource-saving production approach - introduction: value according to the LEAN concept; Five key principles in the LEAN concept; Value stream mapping and analysis; Material flow and material flow optimization tools; Difference between Pull and Push systems; Perfection; Seven losses in the LEAN concept; Operational planning and scheduling; Gantt charts and the LOB method. 2. Lean synchronization and capacity utilization, comparison and integration with MRP methodology: Kaizen; Gemba; LEAN synchronization; Concept of best work practice; List of Materials - BOM; Inputs and outputs of MRP; Production master plan and its inputs. 3. Quality control in production and the 6 Sigma concept: Structural problem solving; Steps of the 8D technique; KPI metrics; Kaizen charter form; Relationship between quality level and potential profit; Statistical process control; 6 Sugma and connection with control charts; DMAIC. 4 Lean 6 Sigma integration and basic tools of practical application: Levels of LEAN 6 Sigma experts; LEAN 6 Sigma techniques and connection with DMAIC stages; Voice of customers method and its application; Stages of new product development and application of QFD and DFM. 5. Experiment design - basic principles and examples from practice: Modeling; Modeling objectives; Five key steps in designing experiments.

1. Identification of Values in the product/service; Monitoring the flow of value and the flow of materials; Analysis of 7 losses; Constriction of balance line - LOB; 2. Creation of the bill of materials (BOM) of the product; Creation of MRP, based on LOB, using QM for Windows application; 3. Identification of metrics (KPI) of the considered process; Construction of X/R using QM for Windows application and PathMaker software; 4. Creating a process flow map; Cause-Effect Diagram (Ishikawa); Pareto diagram; Application of the Why-Why method in identifying the causes of disruptions in the process; 5. Experiment design, application of methods on a practical example.

Enrolled semester.

Handouts from lectures and instructions for exercises. The use of other literature is also recommended, especially during the preparation of exercises.

Total assigned hours: 30

New material: 8
Elaboration and examples (recapitulation): 4

Auditory exercises: 0
Laboratory exercises: 0
Calculation tasks: 4
Seminar paper: 0
Project: 8
Consultations: 0
Discussion/workshop: 0
Research study work: 0

Review and grading of calculation tasks: 1
Review and grading of lab reports: 0
Review and grading of seminar papers: 0
Review and grading of the project: 2
Test: 1
Test: 0
Final exam: 2

Activity during lectures: 0
Test/test: 25
Laboratory practice: 0
Calculation tasks: 15
Seminar paper: 0
Project: 30
Final exam: 30
Requirement for taking the exam (required number of points): 0

B. Popović, M. Klarin, Z. Veljković, Six Sigma System in Realization of Process Results - Processing for Six Sigma, Faculty of Mechanical Engineering UB, 2008; Theisens, H. C. (2020). Lean Six Sigma Green Belt: Mindset, Skill set and Tool set. Van Haren.; Sproull, B. (2019). Theory of Constraints, Lean, and Six Sigma Improvement Methodology: Making the Case for Integration. Productivity Press.; Montgomery, D. C. (2020). Introduction to statistical quality control. John Wiley & Sons.; Handouts - theory and practice