Module: Lean & 6 Sigma Manufacturing

Latest Module Specifications

Current Academic Year 2025 - 2026

Module Title	Lean & 6 Sigma Manufacturing
Module Code	MEC1027 (ITS: MM354)
Faculty	Mechanical & Manufacturing Eng	School	Engineering & Computing
NFQ level	8	Credit Rating	5

Description

The aim of the module is to introduce students to modern manufacturing operations management principles and tools in order to reduce manufacturing costs, improve product quality and increase customer satisfaction.

Learning Outcomes

1. place modern manufacturing operations management within a historical context
2. compare and contrast the main modern approaches to manufacturing operations management
3. financially evaluate projects
4. apply a range of manufacturing operations management tools and techniques to reduce costs, improve product quality and increase customer satisfaction

*Type*	*Hours*	*Description*
Workload	Full time hours per semester
Lecture	24	No Description
Seminars	12	No Description
Independent Study	24	No Description
Directed learning	40	preparation
Independent Study	25	No Description
Total Workload: 125

Section Breakdown
CRN	10230	Part of Term	Semester 1
Coursework	0%	Examination Weight	0%
Grade Scale	40PASS	Pass Both Elements	Y
Resit Category	RC1	Best Mark	N
Module Co-ordinator	Tamas Szecsi	Module Teacher

Type	Description	% of total	Assessment Date
Assessment Breakdown
Group assignment	Group assignment for using six-sigma manufacturing tools.	20%	n/a
Formal Examination	End-of-semester written examination	80%	End-of-Semester

Reassessment Requirement Type
Resit arrangements are explained by the following categories; RC1: A resit is available for both^* components of the module. RC2: No resit is available for a 100% coursework module. RC3: No resit is available for the coursework component where there is a coursework and summative examination element. ^* ‘Both’ is used in the context of the module having a coursework/summative examination split; where the module is 100% coursework, there will also be a resit of the assessment

Pre-requisite	None
Co-requisite	None
Compatibles	None
Incompatibles	None

All module information is indicative and subject to change. For further information,students are advised to refer to the University's Marks and Standards and Programme Specific Regulations at: http://www.dcu.ie/registry/examinations/index.shtml

Indicative Content and Learning Activities

Introduction to manufacturing systems
Types of production (push/pull production, job shop, batch, mass production, mass customisation); Types of manufacturing systems (individual machines, manufacturing cells, FMS, automatic production lines).

Financial calculations
Cost analysis (costs, revenue, profit); Project evaluation (net present value, internal rate of return, payback).

Total Quality Management
TQM principles, methodology, strategies; Cost of quality.

The Toyota Production System
History of TPS; Main concepts of TPS.

Just-in-Time manufacturing
Characteristics of JIT; Kanban systems; CONWIP.

Lean manufacturing
Principles of lean manufacturing; Types of waste; Value stream mapping; Elements of lean manufacturing (5S, autonomation, error prevention, single-minute exchange of dies, production levelling, standardised work, continuous improvement).

Six sigma manufacturing
Statistical basis of six sigma manufacturing; Process capability; Six sigma methodologies (DMAIC, DMADV); Six sigma tools (PICK chart, RACI matrix, Pugh matrix, cost-benefit analysis, critical to quality tree, Taguchi loss function, 5 whys, Pareto analysis, failure mode and effect analysis, data representation, regression analysis, correlation, statistical process control); Six sigma implementation roles; Six sigma criticism.

Dimension analysis
Principles of interchangeability; Full interchangeability; Partial interchangeability.

Indicative Reading List

Books:

Breyfogle, F.W.: 2003, Implementing Six Sigma; Smarter Solutions using Statistical Methods, 2, John Wiley & Sons, Inc., New Jersey,
Monden, Y.: 2012, Toyota production system: an integrated approach to just-in-time, 4, CRC Press, London,
Weiss, N.A. and Hassett, M.J.: 1991, Introductory Statistics, 3, Addison-Wesley, Reading,
Lu, D.J.: 1985, Just-in-Time at Toyota, Revised ed., Productivity Press, Cambridge,
Hay, E.J.: 1988, The Just-in-Time Breakthrough: Implementing the New Manufacturing Basics, 1, John Wiley & Sons, New York,

Articles:
None

Other Resources

Files on Loop: Tamas Szecsi, MM354 module notes,