Developing an Innovative and Creative Hands-on Lean Six Sigma Manufacturing Experiments for Engineering Education

  • I. Elbadawi Industrial Engineering Department, University of Hail, Hail, Saudi Arabia
  • M. Aichouni Industrial Engineering Department, University of Hail, Hail, Saudi Arabia
  • N. A. Messaoudene Mechanical Engineering Department, University of Hail, Hail, Saudi Arabia
Keywords: innovation, creativity, engineering, education, Lean manufacturing, Six Sigma, hands-on


The goal of this study was to develop an innovative and creative hands-on project based on Lean Six Sigma experiments for engineering education at the College of Engineering at the University of Hail. The exercises were designed using junction box assembly to meet the following learning outcomes: 1-to provide students with solid experience on waste elimination and variation reduction and 2-to engage students in exercises related to assembly line mass production and motion study. To achieve these objectives, students were introduced to the principles of Lean manufacturing and Six Sigma through various pedagogical activities such as classroom instruction, laboratory experiments, hands-on exercises, and interactive group work. In addition, Minitab 17 statistical package and Quality Companion 3 software were used to facilitate The Lean Six Sigma exercises. The software application and hands-on manufacturing assembly were found to be extremely valuable in giving students the chance to identify which variables to control in order to minimize variation and eliminate waste. This research was funded by a grant from the Deanship of Academic Research at University of Hail for project number E-26-IC, and under the umbrella of Ministry of Education within the framework of the National Initiative on Creativity and Innovation in Saudi Universities at University of Hail.


Download data is not yet available.


L. Carlson, J. Sullivan, “First year engineering projects: an interdisciplinary, hands-on introduction to engineering”, ASEE Annual Conference, pp. 2039-2043, 1995

I. Elbadawi, D. McWilliams, T. Tetteh, “Enhancing Lean Manufacturing: Learning Experience through Hands-on Simulation Exercises”, Simulation and Gaming Journal, Vol. 41, No. 4, pp. 537–552, 2010

I. Elbadawi, “3D Design Process for Manufacturing and Assembly Table Top Tools for Incremental Continuous Improvement (Kaizen)”, Technology Interface international Journal, Vol. 15, No. 1, pp. 28-34, 2014

A. K. Verma, Simulation Tools and Training Programs in Lean Manufacturing, NSRP-ASE Report No.0301-11, Norfolk, VA: Old Dominion University, 2003

M. L. George, Lean Six Sigma: Combining Six Sigma Quality with Lean Speed, McGraw-Hill, New York, NY, 2002

J. Womack, D. Roos, D. Jones, The Machine That Changed the World : The Story of Lean Production, Harper Perennial, 1991

J. Womack, D. Jones, Lean Thinking, Simon & Schuster, New York, 1996

D. Montgomery, Introduction to Statistical Quality Control, John Willey & Sons, Inc., New York, NY, 2004

G. Ballard, The Last Planner System of Production Control; Ph.D. Dissertation, The University of Birmingham, U.K., 2000


Abstract Views: 358
PDF Downloads: 203

Metrics Information
Bookmark and Share