six sigma

Six Sigma Final Exam for In-class, Lake Campus and Distance students (Fall 2016)

(Due date: Tuesday, December 13, 2016 – 11:59 PM)

All students should email the solutions before the due date to avoid the late penalty.

Use the presentations of in-class students and Lake Campus students for this exam.

Question #1: Use Case Study Presentations on “Six Sigma application in Manufacturing”.

Step1 : Develop a table listing the following 3 columns: Column 1- Four advanced six sigma tools (one on each row).

Advanced tools: Gage R&R, FMEA, Hypothesis testing and Design of Experiment (DOE)

Column 2: List Case study presentation codes in front of each tool where it was used.

Column 3: Total of all codes

Step 2 : Select 2 tools with the highest count in column 3 (In case of a tie select any one)

Step 3 : Discuss how each of the above tools helped the project achieve success. Focus on the importance of the tool in achieving the outcome/results. What impact would it have on the project if the tool was not used? Use two examples to explain your answer in step 3 for each tool.

Total answer for Question 1 should not exceed 2 pages using 12 size font and single spaced.

Question #2: You have joined a small private manufacturing company with old manufacturing philosophy.

2A) Write a memo to John Smith (owner and President) to convince him to start a Six Sigma program in the plant. Grade will depend upon how good a case you can make to convince him.

Memo should not exceed 1 page, 12 size font, single spaced. Use IBC format (see note below)

To: John Smith From: Your name Subject: Benefit of starting a Six Sigma program in our plant

2B) Your memo convinced John Smith to start a six sigma program and he sent you to a Six Sigma conference in Dayton, OH for some ideas on how to Implement (Deploy) a six sigma program in the plant.

You attended the lectures from 3 Six Sigma experts (Tom Black, Scott Wise, and Dennis Broughton)

List 6 ideas (two from each Six Sigma experts) and 4 ideas from class lectures (total 10 ideas) on deployment

Question #3 Use Case Study Presentations on “Six Sigma application in Healthcare”.

3A) Develop a table listing the following 3 columns: Column 1- six basic & intermediate tools (one on each row).

Basic / Intermediate tools: SPC (control charts), Pareto chart, Cause and Effect (Fishbone) Diagram, Histogram, Run chart and Prioritization matrix.

Column 2: List Case study presentation codes in front of each tool where it was used. Column 3: Total of all codes

3B) Compare and contrast the following three groups with 4 bullet points for each group

a) Pareto Chart and Histogram, b) Run Chart and Control Chart, c) Fishbone Diagram and Prioritization Matrix

Examples for Pareto Chart and Histogram:

1. Both use bar charts for analysis

2. Pareto Chart uses 80/20 rule for analysis while Histogram uses the size & frequency of the bars for analysis

Question #4:

Based on what you have learned in the class lectures and film presentations, List 10 actions you will take to improve your Six Sigma program by changing the culture in the plant. Start each sentence with “We should………….”

Example: Action 1: We should install suggestion boxes throughout the plant (Dr. Bharwani)

Questions #5: There were many in-class presentations and lectures, which discussed the reduction of “waiting time” or “employee errors” in healthcare companies and improving “efficiency and performance (reducing scrap & rework)” in manufacturing companies using Six Sigma techniques.

Discuss (with examples) between the Six Sigma approach for healthcare versus manufacturing companies. Focus on the similarity and differences in the approach, tools used, outcomes achieved. List presentation codes when used.

Use IBC format with the heading: Application of Six Sigma in Manufacturing and Healthcare Companies

Not to exceed 1 page, single spaced, font size 12.

Please note:

a) List any outside sources which you have used in this exam on a separate page.

b) You can use your own presentation code as one of the sources for any question.

c) List = 1 sentence. Use single spaced and 12 size font for the whole exam.

d) Use IBC format = Introduction, Body and Conclusion paragraphs for the exam