Operations Management with Six Sigma

Module Name

Topics 

Paradigms of Operations Management 

• Nature of Operations
• Visualising Challenges
• Strategies for operational competitiveness

Design of Products and Services 

• Describe the concepts of Product Design
• Understand different product design criteria (QFD, VA)
• Describe the concepts of Service Design

Capacity Planning 

• Describe the concept of capacity management
• Understand the concept of economies and diseconomies of scale
• Apply break-even analysis for capacity planning

Understand the concept of MRP 

• Understand the concept of Master Production Schedule
• Develop a system structure for MRP

Project Management 

• Project Planning
• Work Breakdown Structure (WBS)
• Organization Breakdown Structure (OBS)
• Responsibility Matrix
• CPM & PERT

Demand Forecasting in SCM

• Characteristics of forecasts
• Classification of forecasting methods
• Measures of forecast error
• Solving forecasting problems using Excel

Inventory & SCM 

• Role of Inventory in SCM
• Inventory Control systems
• Inventory Review Systems
• Managing Uncertainty in SCM

Sourcing Management 

• Sourcing Strategy and its alignment to Business Strategy
• Total Cost of ownership
• Strategic Sourcing Process & Elements
• Risk Management in Sourcing
• Supplier selection & evaluation
• e-Procurement

Designing Supply Chain Networks 

• Role of network design in supply chains
• Factors influencing network design decisions
• Framework for network design decisions

Managing Information Flows and Bullwhip Effect in Supply Chain 

• Understand important supply chain strategies like postponement, risk pooling

Understand the Analytics Framework 

• Decision Domain in Supply Chain Analytics
• Supply Chain Analytics Process Framework
• Contemporary Analytics Framework

Supply Chain Analytics Modelling

• Descriptive Analytics
• Predictive Analytics
• Machine Learning in Analytics

Decision Modelling 

• Introduction to steps in problem solving
• Quantitative analysis and decision making
• Models for decision- making
• Introduction to Linear Programming

Logistics Management 

• Distribution, Transportation, Warehousing, Information technology
• Logistics integration, Outsourcing
• Omni-channel logistics; Downstream Management; End Consumers; Logistics restructuring

Transportation and Assignment Problems 

• Formulation and Solution to Transportation problems
• Formulation and Solution to Assignment problems

Quality Overview 

• Defining the Quality
• Phases of Customer Satisfaction
• TQM Models
• Quality Management Gurus

Quality Management System 

• Using Process Approach to build Quality Management System
• Quality Management System ISO 9001/Quality accreditation systems

Understanding Lean and its Applications 

• Introduction to Toyota Production System
• History, Philosophy and Applications across various sectors and domains
• Flow Efficiency Vs. Resource Efficiency
• Lean Vs Six Sigma, Lean Six Sigma
• Types of Waste MUDA, MURA, MURI
• Value Stream Mapping

Six Sigma Overview 

• Six Sigma Philosophy
• Origin of Six Sigma
• Six Sigma Evolution
• Six Sigma Approaches

Recognise Phase 

• Create Organization for Six Sigma
• Create Project Hopper
• Select a Project
• Project Prioritization Matrix

Define Phase 

• Ensure that the project is important
  • Project Charter
• Identify the stakeholders and understand their concerns/ requirements connected to the problems
  • VoC/ VoS
  • Kano Model
  • VoS Template
• Define the measures to represent the concerns/ requirements in terms of Critical to Quality (CTQs)
• Map the macro-level process which consists of the causes and the effect
  • SIPOC

Measure Phase

• Introduction to basic Statistics
• Process Stability Analysis - Normality
• Data Collection Planning
• Collection Methods
• Theory of Sampling
• Root Cause Analysis
• Measurement System Analysis

Analyse Phase 

• Analyse the problem to ascertain the status of the problem as chronic, sporadic and unstable
  • Control Charts-Variable, Attribute
• Analyse the process to identify process flow relate real causes
  • Process Maps

Analyse Phase 

• Conclude real causes with estimated confidence
  • Test of Hypothesis
  • Steps for Test of Hypothesis
• Normality test, 1 Sample-t-test, 2-Sample-t-test, One-Way ANOVA,; Chi-square test

Control Concepts 

• Confirm Improvements: Before-After:
  • Test of Hypothesis
  • Process Capability
  • Pareto Diagram
  • Control chart
  • Process Map
    • Ensure on-line control of improved status
    • Ensure on-line control of improved status
  • Document, Standardise & Integrate

Operations Manager 

Quality Manager 

Process Improvement Specialist 

Supply Chain Manager 

Lean Manager 

Project Manager 

Manufacturing Engineer 

Logistics Manager 

Process Engineer 

Continuous Improvement Analyst