six sigma

MGMT 405 – E-LEARNING SPRING 2020

MGMT 405: Six Sigma & Quality Management

Final Week Assessment (20%)

Due Date: Tuesday, 09/06/2020

E-LEARNING SPRING 2020

Instructors: Dr. Mazen Arafah / Dr. Ridvan Aydin

Student Name & ID : Section:

Question Earned Points Max. Points

1 40

2 25

3 20

4 15

Total 100

 Make sure your submission is complete (You answered all four questions).

 Make sure your submission is eligible, readable, and clear.

 The assignment is due on Tuesday, June 9th midnight, delays will result in cutting your grade

according to announced AUM policy.

Question 1 (40 points)

Assume you, an Industrial Engineer, are conducting a Six-Sigma Project on minimizing

defects and improving processes in Ikea or Safat Home. Develop a Failure Mode and

Effect Analysis (FMEA) to define potential process or product risks.

Use Microsoft Excel to construct a complete FMEA tool by

A. Identifying two possible failure modes for service/shopping experience in Ikea

or Safat Home. [20 points]

B. Calculate the corresponding Risk Priority Number (RPN). [8 points]

C. Recommend action plan for eliminating the corresponding failure modes and

improving the process and product quality. [12 points]

Question 2 (25 points)

Identify and explain five error-proofing examples implemented in a manufacturing

facility.

Question 3 (20 points)

100 bottles entered a bottle-filling process that has three main stags. The first one

has three possible failures. The second has four possile failures. The third has five

possible failures.

The first stage produced 27 defects. The defects were found in 10 bottles.

The second stage produced 57 defects . The defects were found in 15 bottles.

The third stage produced 64 defects. The defects were found in 20 bottles.

Determine: 1. DPMO [10 points]

2. SQL (Approximately) [5 points]

3. PPM [5 points]

Question 4 (15 points)

Suppose that the defects found in five bottles in first stage were fixed, and the

defects found in ten bottles in the second stage were fixed, and the defects found in

ten bottles in the third stage were fixed.

Determine and explain each of the following:

4. FTY for each of the three stages [6 points]

5. FPY for each of the three stages [6 points]

6. RTY using the FTY [3 points]