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This course will teach a focused managerial strategy of process improvement and variation reduction called Six Sigma, 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.
To this end this course will span established methods of quality assurance and management, and advanced statistical methods including design of experiments.
Positioned at the frontier of modern quality strategies, Six Sigma comprises two frameworks-DMAIC (define, measure, analyze, improve, control) and DMADV (define, measure, analyze, design, verify). This course will cover both.
Basic concepts in Quality Engineering and Management: definitions, approaches and relevance to organizational excellence.
Probability and Statistics-a review.
Total Quality Management perspective, methodologies and procedures; Roadmap to TQM, ISO 9000, KAIZEN, Quality Circles, Quality Models for organizational excellence.
Cost of Quality concepts; finding incentives for improving quality.
Overview of Project Management.
Measurements, Accuracy, precision, Gage R & R.
Product quality control: Acceptance sampling methods-single, multiple and sequential sampling plans; Recent developments in inspection methods.
SPC: Process evaluation and control by control charts: p, c, u, CUSUM and multivariate charts.
Process capability studies: Various indices and approaches; Discussions on capabilities of Process, Machine and Gauge.
Six Sigma Concepts, Steps and Tools.
Quality Function Deployment, QFD example.
Process evaluation and imp-Improvement by Design of Experiments: Various basic designs; Special methods such as EVOP and ROBUST design (Taguchi Methods).
Case Study of Orthogonal Array application.
Robust design by Taguchi Methods.
Case Study of product design by Taguchi Philosophy.
DMAIC-Define, measure, analyze, improve and control-the methodology of Six Sigma implementation.
DMADV-Define, Measure, Analyze, Design and verify-the methodology for creating high performance designs.
Justifying Six Sigma: a Manufacturing Case.
Readiness for Six Sigma-assessing the Organization.
Case Study of initiating Six Sigma DMAIC in Manufacturing.
TQM vs. Six Sigma-The contrast.

Other Resources

Course Curriculum

Mod-01 Lec-01 Concepts in Quality Management – I Details 54:42
Mod-01 Lec-02 Concepts in Quality Management – II Details 56:12
Mod-01 Lec-03 Concepts in Quality Management – III Details 59:4
Mod-01 Lec-04 Initiating Six Sigma Details 58:25
Mod-01 Lec-05 Review of Probability and Statistics – I Details 55:57
Mod-01 Lec-06 Review of Probability and Statistics – II Details 57:8
Mod-01 Lec-07 Review of Probability and Statistics – III Details 57:13
Mod-01 Lec-08 Review of Probability and Statistics – IV Details 56:33
Mod-01 Lec-09 QM Systems Overview Details 58:14
Mod-01 Lec-10 Cost of Quality and TQM Tools Details 58:25
Mod-01 Lec-11 QFD and ISO 9000 Details 56:11
Mod-01 Lec-12 QS 9000 and Awards Details 56:15
Mod-01 Lec-13 Competing Through Service Quality Details 57:8
Mod-01 Lec-14 Introduction to Project Management Details 52:42
Mod-01 Lec-15 Project Life Cycle Details 54:24
Mod-01 Lec-16 Critical Path Method Details 59:23
Mod-01 Lec-17 Measurement System Analysis Details 57:15
Mod-01 Lec-18 Acceptance Sampling Details 55:56
Mod-01 Lec-19 Design of Sampling Plans Details 56:30
Mod-01 Lec-20 MIL-STD-105E Sampling Plan Details 55:39
Mod-01 Lec-21 Introduction to SPC Details 55:37
Mod-01 Lec-22 Control Chart Examples Details 57:17
Mod-01 Lec-23 Control Charts by Excel Details 54:27
Mod-01 Lec-24 Process Capability Details 54:48
Mod-01 Lec-25 Quality Function Deployment Details 50:36
Mod-01 Lec-26 Design of Experiments – Overview Details 54:16
Mod-01 Lec-27 Planning for DOE Details 56:6
Mod-01 Lec-28 Factor Effect Calculations Details 55:10
Mod-01 Lec-29 ANOVA in DOE Details 54:54
Mod-01 Lec-30 Benchmarking in Six Sigma Details 54:50
Mod-01 Lec-31 How to Benchmark Details 57:44
Mod-01 Lec-32 Six Sigma in Supply Chains Details 56:22
Mod-01 Lec-33 Taguchi Methods Details 56:51
Mod-01 Lec-34 Robust Design Details 57:8
Mod-01 Lec-35 The Journey to Six Sigma Details 55:1
Mod-01 Lec-36 A Case Study of Defect Reduction Details 55:43
Mod-01 Lec-37 DFM & Reliability Details 54:50
Mod-01 Lec-38 Failure Modes & Effects Analysis (FMEA) Details 56:48
Mod-01 Lec-39 Implementing Six Sigma Details 56:30
Mod-01 Lec-40 Getting Results From Six Sigma Details 54:28

These video tutorials are delivered by IIT Kharagpur as part of NPTEL online courses program.

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