INSTRUCTOR:  Jim Wixson (Cell) 208-520-2296

 Email:  jwixson2@gmail.com (personal) jrwixson@wvasolutions.com (company email)

University of Idaho Home Page:  http://avanti.if.uidaho.edu/~wixsjr/uofihome.htm

Wixson Value Associates, Inc. website on Value Engineering: http://wvasolutions.com

CDs:  Course CDs will be mailed to each students address listed in their current student information area on Vandal Web.  If this is outdated, or, another address is desired to send the CDs to, please contact the instructor immediately.  CDs will be mailed in time to reach students by the time the semester starts.

Blackboard :  Click here for the Blackboard main page.

Blackboard Help:  Click here for the ITS Helpdesk

Class Dates:  8/24/2009 thru 12/18/2009

One Line meetings:  Every Tuesday 8:00 - 9:30 PM.  Notices and instructions to be sent out by email to entire class.

A BRIEF NOTE: This syllabus and schedule are subject to change, so, please check back on the web site frequently, at least once a week, to note any changes.

ABOUT THE ONLINE SCHEDULE:    I will make the quizzes and exams available well ahead of when they are required to be taken.  I would encourage everyone to work ahead and take the quizzes early.  You will have two chances for each quiz. You will receive the highest score for your grade on the quizzes. You will be allowed only one attempt on the midterm and final exams and you will have 120 minutes to complete each exam once you have started it. Both the quizzes and exams are comprised of multiple choice questions. I would encourage you to work ahead of the schedule so you can spend more time on your project.  Please don't hesitate to call, or email me if you are having problems.  Thanks,  Jim Wixson

DISABILITY SUPPORT SERVICES: Reasonable accommodations are available for students who have documented temporary or permanent disabilities.  All accommodations must be approved through Disability Support Services, located in the Idaho Commons Building, Room 306. Please contact Disability Support Services as soon as possible so that you may receive accommodations in a timely manner.

·         208-885-6307

·         email at  <dss@uidaho.edu>

·         website at <www.access.uidaho.edu>

Students with any disability should present a completed and signed Accommodation Checklist for the current semester available from Disability Support Services when requesting accommodations.

REQUIRED TEXTS:

1. Juran's Quality Planning and Analysis for Enterprise Quality, 5th Edition

Publisher: McGraw-Hill Companies, The

Pub. Date: December 2005

ISBN-13: 9780072966626

Sales Rank: 378,787

704pp

Series: McGraw-Hill Series in Industrial Engineering and Management Science

Edition Description: REV

Edition Number: 5

Publisher: Simon & Schuster Adult Publishing Group
ISBN: 0743249275
Format: Hardcover, 396pp
Pub. Date: June 2003

Highly Recommended Reading

3.  Value Engineering for the Practitioner
 

·  Hardcover: 202 pages

·  Publisher: North Carolina State University,                 College of Eng'g; 2 edition (August 1989)

·  Language: English

·  ISBN-10: 1560490004

·  ISBN-13: 978-1560490005

(Also available from Amazon.com)
 

The trademark of this course is to develop the viewpoint that the achievement of quality products and services requires the application of managerial, technological, statistical, and behavioral actions throughout all functions of an organization. Students will be presented with real-world problems that confront managers, designers, engineers, marketers, operations personnel, users, and others involved in enterprise quality. This course will challenge students to make assumptions, estimate economics, reach data-driven conclusions, and adapt themselves to the imperfect world of the practitioner. 

A cornerstone of this course is the class project which can be completed either individually, or by small groups.  A teaming approach is encouraged since this is the way projects of this type are accomplished in industry today.  It is recognized that this may not always be possible due to the remote nature of this course.  However, students are encouraged to collaborate whenever possible.  It is encouraged that these projects be work related, or performed at companies, or organizations students may have some involvement with.  In the past, students have accomplished some very dramatic results that serve to cement the concepts of this course and illustrate the usefulness of the techniques that are taught.  These results have not only benefited the students, but, also these companies, or organizations where they were performed.

This course will provide a foundation and knowledge about Quality Assurance and Management.  It is designed to be a interactive course that will provide students with a basic knowledge of current methodologies and management of Quality Assurance and Quality Organizations.  An emphasis will be placed on industrial management principles applied to effective economic control of quality assurance activities.  Methodologies such as Six Sigma, Total Quality Management, Lean Manufacturing, Value Stream Mapping, Failure Modes and Effects Analysis (FMEA), Statistical Process Control, Designing for Quality, and Value Engineering will be discussed and explored.  Key principles from these methodologies will be taught.  I recognize that this is an aggressive agenda.  However, the goal is to become familiar with these principles so the student will be encouraged to use these in future endeavors in the workforce.  The capstone of this class will be the class project where the students will tour a local company and choose tools from this "tool box" and use them to develop improvement scenarios that will be presented to the company management at the end of the course. 

METHODS OF INSTRUCTION:

Lectures for this course are provided via a CD that will be mailed to students prior to the commencement of the semester.  The lectures are in MS PowerPoint format and are narrated by the instructor.  There are several short movies delivered via streaming video on the CDs to add emphasis to the lectures.  Quizzes and exams are delivered through Blackboard which will be made available to each student.  Grades will be determined on the basis of quiz scores, homework, a mini project and a final exam.  Also, I encourage students to use the discussion and chat tools on blackboard. 

Students will be expected to have a firm grasp of the homework problems found in the back of each reading assignment.  The primary focus of the homework problems will be to be able to discuss them in class.  Most of the homework problems will be worked in class and can be worked on in small groups.  Then, the problem solutions will be discussed in class. 

Students will be expected to complete a class project that utilizes at least 5 of the principles taught in a cohesive way that will lead to an end result, conclusions and recommendations for improvement.  It will be highly encouraged that this be a group project.  An economic analysis and justification of the recommendations will be required.

In my class, most of our work will be completed by your group and presented by members selected by your group.  I expect that each member of the group will pull their own weight and contribute to the group assignments.  I will also assign homework assignments out of our text.  These may be worked on either individually, or in your group.  I believe that better results are gained from group discussion and interaction.  We will discuss the homework in class and I would like each member of the group, or team to have an opportunity to present the solutions, or conclusions to the homework problems.  I may also determine that a take home final is warranted.  This will be the only time I expect individual work.  In the case of the take home final exam, if any, the rules and expectations dealing with Academic Dishonesty as outlined in the Student Affairs Policy Chapter 2 will apply.

Classroom: Each class is planned to help students learn the concepts and tools that can help them effectively manage output quality. Thus, attendance is important for student learning.

Participation and preparation: Student preparation is important for learning. Participation in on-line/email discussions helps the student solidify their understanding and helps classmates gain another perspective. Participation is strongly encouraged. This course is designed to be non-threatening and interesting where new ideas can be explored.  Questions and thoughts are always welcome. It is better to make a mistake than to withhold idea sharing.

In a continuous improvement environment it is important that all organization members contribute to management understanding of potential improvements. This class will stress continuous improvement; therefore, individual students or teams of students will be expected to make suggestions on ways to improve the system in order to increase learning efficiency and effectiveness.

Textbook, Readings, Small Cases and Assignments

The textbook, readings, small cases and assignments are purposefully organized and assigned. All the readings are important. They are not assigned evenly throughout the semester; therefore, students are encouraged to plan ahead and read future assignments during time periods when reading assignments are not as heavy.

During the semester there are few written assignments that must be handed in / emailed to me.  In the on-line version of this class, assignments can either be emailed, or submitted through Blackboard. Students will be supplied a CD with all of the lectures in PowerPoint format. The majority of these lectures are narrated and animated. As such, it is important that each on-line student email  the instructor an address where the CD can be mailed to.  

Late Assignment Policy:

Assignments are by Sunday 11:59 PM of the week shown on the schedule.  There will be a 5 point penalty per week late assessed on any late assignments and a 10 point per week penalty on the final project.  In the event of any extenuating circumstances that cause the delay of any assignment, please notify the instructor as soon as these circumstances are encountered, but, no later than 48 hours prior to the final due date of the assignment.  Please contact me if you have any questions.

Team project/quality project: A quality improvement project is required for successful completion of this course. The intent is for this to be a live or real-time project that comes from your job, or some company/organization you are closely associated with and can get access to the management and staff to collaborate with. This is not intended to be a case study from a management, or similar text.  However, some exceptions may be made depending on each individual student’s circumstances.

Since this is an on-line course and students are widely dispersed, projects will most likely be worked by individuals. I would encourage each of you to collaborate as much as possible with your fellow classmates on your individual projects. If you can find a way to work the project as a team, that’s great.  However, recognize that each member of the team will receive the same grade for the project.  Therefore, make sure that the work is spread evenly between the team members so the grade for each is representative of the effort expended.

The emphasis of this project is quality, or process improvement. Ideally, this will be a value-engineering study for improvement of a product, process, or service. The project can also be based on lean principles, six-sigma, or any combination of these or other improvement methodologies. The project should include an estimate of the cost and benefits gained, both tangible and intangible, from implementation of the project.  A FAST Model of a product, process, or service with an accompanying cost/function matrix (could be based on hours also) should be completed as part of the project.  The final project will be in the form of a PowerPoint management presentation.  This presentation will be given to the class via GotoMeeting, or other suitable group internet meeting tool.

Project Guidelines:

Try to think of something at work, home, or anywhere else, even another company that you have access to that is a problem.  That problem could be poor quality, safety issue, wasted time, space, talent or other source of waste.  Then, try to clearly define the problem and, if possible, quantify the waste, or the problem.  (I don’t expect you to quantify the problem for your proposal, however.) This can be just a ballpark estimate, but, something that is realistic.  It may be hard for me to help you too much without talking with you.  So, feel free to call and discuss your ideas with me.  But, I suspect you can think of something that is a big issue that might be a potential project.

 Of course, before you start work on any project related to your employment you should discuss this with your management and get their approval.  Ideally, this project should benefit both you and your employer.  Also, make sure you are not violating any company guidelines, or confidentiality regulations.  Quantification of the problem can be expressed in man hours, percentages, or other metrics that won’t compromise any company labor rates, or other confidential financial data.  I would like to see a discounted cash flow analysis of any cost savings versus implementation costs if you can.  You could possibly normalize the data such that proprietary information is masked.  I would discuss this with your management as well if your project might touch on this area.  Please let me know if any of these might be issues. 

Any of the general techniques taught in the course could be used.  These include Value Analysis/Value Engineering, Six Sigma, or Lean Management techniques, or a combination of these.  I am looking for the following general attributes for the project:

1. Problem identification and Solution Skills
2. Use of problem solving tools taught in this class, or any other tools that might apply and I approve.
3. Creativity in problem solving.
4. Ability to build a good business case for solving the problem.
5. A clear presentation of the problem to include:
1. Problem identification
2. Analysis
3. Development of Alternatives
4. Evaluation of Alternatives and development of one or two preferred alternatives
5. Report on the results of your study and summarize conclusions and recommendations.

You may also consider using the DMAIC process from six sigma.  That is: Define, Measure, Analyze, Improve and Control.  Or the Value Engineering 6 step process. 

Examples:

1.       A Value Engineering/Analysis study of project, or of a suitable problem at work, home, or elsewhere.  Could be from a case study.

2.       Application of Lean Management including a Value Stream Map of some process showing identifying the waste in the system, the value added activities, and ratio of value added to waste, and an estimate in hours, or dollars of the opportunity for improvement.

3.       A root cause analysis study to determine the cause of defects in a product, process, or service and an action plan for improvement including estimated costs, schedule, and identified roles and responsibilities for accomplishment of the action plan.

4.  Any other suitable proposal for process/product improvement analysis approved by the professor.

To receive full credit, the analysis must include:

a. An explanation of the problem.
b. An explanation of the process used to analyze the problem and how it was used to analyze the problem.
c. The results of the analysis.
d. Recommendations that could be derived form the analysis.
 

Another important point is that I don’t expect implementation of the project.  However, that would be nice.  But, I would like to see an implementation plan in the form of a schedule of activities that need to be done to implement the solution.  This is especially important if you are going to do a discounted cash flow analysis.  I’ll consider this as extra credit for the project if you can get this far.  

Midterm: There will be a midterm exam consisting of 20 questions of mixed type.

Final Exam:  This will be an in-class test consisting 20 questions of mixed type.

1. Quizzes - 900 pts
2. Homework - 400 pts
3. Midterm - 200 pts

4.  Project Proposal – 50 Pts

5. Project - 250 pts
6. Final Exam - 200 pts
Total points possible - 2,000

TERM PROJECT:

The emphasis of this project is quality, or process improvement. Ideally, this will be a value-engineering study for improvement of a product, process, or service. The project can also be based on lean principles, six-sigma, or any combination of these, or other improvement methodologies. The project should include an estimate of the cost and benefits gained, both tangible and intangible, from implementation of the project.  A FAST Model of a product, process, or service with an accompanying cost/function matrix (could be based on hours also) should be completed as part of the project.  The final project will be in the form of a PowerPoint management presentation.  This presentation will be given to the class via Blackboard, or other suitable group internet meeting tool.

Examples:

1.       A Value Engineering/Analysis study of project, or of a suitable problem at work, home, or elsewhere.  Could be from a case study.

2.       Application of Lean Management including a Value Stream Map of some process showing identifying the waste in the system, the value added activities, and ratio of value added to waste, and an estimate in hours, or dollars of the opportunity for improvement.

3.       A root cause analysis study to determine the cause of defects in a product, process, or service and an action plan for improvement including estimated costs, schedule, and identified roles and responsibilities for accomplishment of the action plan.

4.  Any other suitable proposal for process/product improvement analysis approved by the professor.

To receive full credit, the analysis must include:

a. An explanation of the problem.
b. An explanation of the process used to analyze the problem and how it was used to analyze the problem.
c. The results of the analysis.
d. Recommendations that could be derived form the analysis.
 

Requirements for a A:
1,800 pts or more
Requirements for a B:
1,600 - 1,799 pts
Requirements for an C:
1,400 - 1,599 pts

Course Schedule

Class

Week Of

Topic

Activities & Reading Assignments

1

8/24

Topics:
Purposes Expectations
Questions
Course syllabus and requirements

Lecture 1:  Overview of various quality methodologies

Video:  Carving a Career in Quality by Philip Crosby  (Must have DSL or Cable to watch)

Basic Concepts
Company wide Assessment of Quality
Quality Improvement and Cost Reduction

Get acquainted with class and instructor 

Discuss class goals and expectations 
 

Juran - Ch 1 - 3,

Homework Assignment #1 (Due 9/14): 
CH 1: 1, 2, & 4 
CH 2: 1, 4, & 5 
CH 3: 2, 3, 5, & 6 

2

8/31

Topics:
Organization for Quality - Ch 8
Developing a Quality Culture - Ch 9.
Understanding Customer Needs - Ch 10.

QUIZ 1 - 100pts

Reading:
Juran - Ch 8 - 10

Homework Assignment #2 (Due 9/28):
CH 8: 2, 3, & 5
CH 9: 3, 5 & 7
CH 10: 2, 3, 6, & 7

3

9/7

PROCESS MANAGEMENT,
INTRODUCTION TO SIX SIGMA
 

QUIZ 2- 100pts

Video: Manufacturing Insights: Six Sigma, Society of Manufacturing Engineers, Dearborn, MI - 30 min.  (Must have DSL or Cable to watch)

This program explains what Six Sigma is and shows how companies are using the methods to find permanent solutions to difficult problems. 

Gretag Imaging (Chicopee, MA), used Six Sigma to improve customer satisfaction by solving a difficult logistical problem. 

Ortho Clinical Diagnostics (Rochester, NY), applied Six Sigma problem solving techniques to discover a measurement discrepancy in an air compressor. This information helped redesign a new compressor that operated within specifications. 

Lockheed Martin (Moorestown, NJ), has applied Six Sigma concepts throughout its entire organization being careful to align projects to the strategic goals of the organization. 

Juran - Ch 5 - 6
 

4

9/14

Topics:
Muda
5 Principles of Lean: 
Value, Value Stream, Flow, Pull, Perfection
Value Stream Mapping 
Value Stream Management 
Push vs. Pull 
Kaisen
Continuous Improvement

HOMEWORK ASSIGN #1 DUE - 100 pts
QUIZ 3 - 100pts

(Hint - read in advance)

6

9/21

Film:  Principles of Value Analysis/Value Engineering, N.C. State University, Raleigh, N.C. - 34 min (Must have DSL or Cable to watch)

Function Analysis Overview and Practice,
Link Function Analysis to Root Cause Analysis

Root Cause Analysis: Never Stop Asking "Why"

Work on Proposals for Class Project
Start Information Gathering, Function Analysis, and Root Cause Evaluation on Class Projects - Use Brainstorming, and other Facilitation techniques to gather information, analyze functions, and categorize causal factors.

QUIZ 4 - 100pts

Proposals for Class Project are Due

Reading Assignment:
The Development of an ES&H Action Plan using Management Oversight and Risk Tree Analysis and Function Analysis Systems Technique , J. R. Wixson, 1992 SAVE International Conference Proceedings, Pgs 29 -36

Value Managed Failure Analysis and Product/Process Improvement, J. R. Wixson, 1997 SAVE International Conference Proceedings, p 276 - 283

Functional Analysis and Decomposition using Function Analysis Systems Technique, J. R. Wixson, International Council on Systems Engineering (INCOSE) 1999 Annual Symposium, Brighton, England, 1999 Conference Proceedings, p. 963 968

CREATING VALUE WITH
LEAN THINKING AND VALUE ENGINEERING
Charles L. Cell Boris Arratia
Headquarters, U.S. Army Joint Munitions Command
Rock Island Arsenal
Rock Island, IL, 61299-6000, USA 309/782-4132

7

9/28

Statistical Tools for Analyzing Data
Measuring Project Sigma: How Close Are You to Perfection?
Continue Developing Class Project in Groups 

Proposals for Class Project Due - 50 pts Due

HOMEWORK ASSIGN #2 DUE -  100 pts.
QUIZ 5 - Value Analysis/Value Engineering - 100 pts 

Homework Assignment #3 (Due 10/5):
Juran Chapter 17: 
2, 5, 6, 8, &11

Homework Assignment #4 (Due 10/5): 
Juran Chapter 18: 
1, 2, 8, 9, & 14

8

10/5

Statistical Tools for Analyzing Data
Measuring Project Sigma: How Close Are You to Perfection?

Continue Developing Class Project - Start to Develop Quality Improvement Model.

HOMEWORK ASSIGN #3 & 4 DUE -  200 pts.

Quiz #6 Chapters 10 & 11 - Statistics - 100 pts

Juran - Ch 20

9

10/12

MIDTERM ON EVERYTHING WE HAVE DISCUSSED TO THIS POINT

10

TOP

10/19

Work on project - Gather Information & Define the Problem

• Answer the 3 questions
• Identify requirements
• Identify constraints (sacred cows)
• Develop selection criteria. 

QUIZ 7, Statistical Process Control - 100 pts

11

10/26

LECTURE 8:  ECONOMIC ANALYSIS OF ALTERNATIVES 

Net Present Value and Internal Return on Investment Calculations

Work on project -

• Complete Function Analysis, Process Flow, or Value Stream Map (VSM). 
• Dimension FAST Model, or identify inefficiencies in Process Flow/VSM

12

11/2

 LECTURE 9:  DESIGNING FOR QUALITY
Designing for Quality - Quality Function Deployment

See: http://www.npd-solutions.com/qfd.html

Work on project -

• Brainstorm Improvements to Functions, or process steps. 
• Combine ideas to develop improvement scenarios.
• Score and evaluate ideas.

13

11/9

LECTURE 10 - DECISION ANALYSIS 
Selecting Solutions That Drive Sigma Performance 
Develop Selection Criteria for Comparison of Alternatives 
Pairwise Comparison of Criteria 
Rank and Rate Alternatives using weighted criteria 

Work on project -

• Select best idea/ideas
• Determine implementation plan and costs (if possible)
• Put together PowerPoint report
• Get ready for dry run with instructor.

Quiz #8 - Economic Analysis - 100 pts

14

11/16

Work on project -

• Incorporate instructor comments and improvements

Reading:

Juran - Ch 11

15

11/23

FALL RECESS

11/29

QUIZ 9:  Designing for Quality

15

11/30

 Course Project Due

16

12/9 – 12/18

12/21

Grades Due

Download Syllabus in pdf format
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