Foundations of Lean Six Sigma

This unit introduces foundational Lean Six Sigma and process-thinking concepts applied to metals manufacturing. Students learn process basics (mapping, VOC, Kano), introductory DMAIC project definition, variation and prevention concepts, and complementary approaches (DfSS, design thinking, Agile, TOC) to define and scope improvement efforts and secure stakeholder acceptance in preparation for deeper measurement and analysis.

Learning Objectives

• Analyze core Lean and Six Sigma principles to identify value-added and non-value-added activities within metals manufacturing processes
• Apply process-mapping, SIPOC/Value Stream Mapping, and Kano/Voice-of-the-Customer techniques to create high-level process representations and translate customer needs into measurable project requirements
• Demonstrate the ability to define concise project scope and briefs using DMAIC entry tools, theory of constraints concepts, and stakeholder acceptance strategies
• Evaluate common types of variation and prevention tools (standard work, DfSS, design thinking, Agile) to recommend initial, prioritized improvement and rapid-improvement ideas