Module Title Module Code

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Module Information Lean Operations and Management of Lean Organisations EMM2515

MODULE SUMMARY

Aims and Summary The aim of this module is to enable the students to identify and eliminate waste / non-value adding activities at all levels to improve business competitiveness. Students will be taught lean tools and techniques and value stream mapping. Assessment of transformation to lean and management of lean organisation will be discussed. Effect of implementation of lean concepts in fortune five hundred companies will be discussed through case studies. Module Size and Credits Module size CATS points ECTS credits Open / restricted Availability on/off campus Total student study hours Number of weeks Department responsible Academic Year Single 10 N/A Restricted On Campus 100 5 weeks Full-Time or 8 weeks Part-Time Department of Mechanical and Manufacturing Engineering 2012

Entry Requirements (pre-requisites and co-requisites) Normally to be qualified for entry to the Postgraduate Engineering Programme Excluded Combinations None Composition of Module Mark (including weighting of components) Full-time / Part-time : 50% Written Examination and 50 % Assignment Pass Requirements A minimum of 40 % marks in the written examination and a minimum of 40% marks in the assignment and overall 40% marks are required for a pass Special Features 80% attendance in theory and 80% attendance in laboratory are required. It is likely that considerable time will be spent in School facilities outside of normal timetabled class time. Courses for which this module is mandatory M.Sc. [Engg] in Engineering and Manufacturing Management

Courses for which this module is a core option M.Sc. [Engg] in Technology and Engineering Management

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TEACHING, LEARNING AND ASSESSMENT On completion of this module the student should be able to: 1. Evaluate the current operational practices in industries 2. Apply analytical techniques to identify and eliminate the seven types of wastes 3. Analyse value stream mapping to appraise the current state and to develop a vision for the future 4. Implement Lean techniques and manage transformation 5. Demonstrate the ability to manage and sustain a Lean organisation

Intended Module Learning Outcomes

Indicative Content Class Room Lectures 1. History of Lean manufacturing and the Need for Change :Evolution of lean, Contributions of Taylor, Gilbert, Ford, Solan and Toyoda family 2. Current Industrial Requirements, Practitioner Thinking, People Issues: New economics of lean, House of lean, Different kind of wastes 3. Total Quality Management.: Introduction and Definition of TQM, Customers and Producers perspective on Quality, Framework and Steps in Implementing of TQM and Employee Involvement 4. Visual Management: 5S, Poka yoke, Jidoka, Andon, Yamazumi board, Kanban, Performance measures, TPM and OEE 5. Waste Identification and Elimination Techniques: Wastes, Pareto, Product flow analysis, String diagrams, Cluster analysis, Non value added analysis, Single Minute Exchange of Die (SMED) 6. Pull Production: Kanban, Rules of kanban system Standard operations, Capacity charts, Walk diagrams 7. Manufacturing Cell Design: Flow lines, Nagare cells, Standard cells, Work allocation, Cell layout 8. Value Stream Mapping: Current state mapping, Lean Metrics, Line balancing, Load levelling, Lot sizing, LFL, Dependent demand, Independent demand, POQ, EOQ, EMQ, Future state mapping and Implementation plans 9. Change Management: Demand patterns, Competitive forces, and Organisational change in engineering businesses 10. Financial Control: Existing financial control systems, Activity Based Costing, Target pricing, Costing and Fixed cost reduction. Laboratory Practice/ Industrial Visit 1. Students shall visit industries practicing lean manufacturing to prepare case studies and discuss the same in class presentations

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Teaching and Learning Methods 1. Theoretical Knowledge a. Face to face lectures 30 hours 2. 3. Laboratory Practice (Skills) 30 hours Application Orientation and Problem Solving a. Reading b. Research c. Written Examination d. Assignment Solving and Documentation 40 hours

Method of Assessment Part-A Examination [50% Weightage] 1. 2. 3. Part B Assignment [50% Weightage] Students are required to submit a word processed assignment report. Viva/Presentation on a specified topic............................................... (10%) Field work / Laboratory test............................................... (10%) Written examination...........................................................................(30%)

Assessment Learning Outcomes Part A Part B 1 X 2 X X 3 X X X X 4 5

Both written examination scripts and assignment reports will be double marked. Re-assessment A minimum of 40 % marks in the written examination and a minimum of 40% marks in the assignment are required for a pass in the module. A student failing in any one of the components or both is considered as FAIL in the module. A failed student is required to retake the module at the next opportunity. A maximum of 3 attempts including the original are allowed. Date of Last Amendment November -2011

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MODULE RESOURCES

Essential Reading 1. Module Notes

Recommended Reading Books 1. 2. 3. 4. Rother and Shock. (1999) Learning to See, Lean Enterprise List D. Tapping. (2002) Value Stream Management, Productivity Inc Womack and Jones. (2003) Lean Thinking, Free Press Dennis Hobbs. (2004) Lean manufacturing: complete execution manual for any seize manufacturing, J Ross 5. Santos. (2006) Improving production with lean thinking, John Wiley 6. Bill Carreira. (2007) Lean manufacturing that works: powerful tools for dramatically reducing waste, Prentice hall 7. AME. (2007) Lean administration case studies in leadership and improvement, Productivity press 8. James Huntzinger. (2007) Lean cost management for lean by establishing flows, J Ross 9. Chris Harris and Rick Harris. (2007) Developing a lean work force, Productivity Press 10. Greg Lane. (2007) Made To order lean: Excelling in a high mix- low volume environment, Productivity press Journals 1. 2. 3. International Journal of Operations and Production Management, Emerald Group Publishing Limited Journal of Manufacturing Technology Management, Emerald Group Publishing Limited International Journal of Productivity and Performance Management, Emerald Group Publishing Limited Industry 2.0

Magazines 1.

Videos 1. Quick Changeover for lean manufacturing 2. Customer focused manufacturing 3. Mapping your value stream 4. Visual control 5. Five S Factory makeover 6. Learning lean through simulation 7. Break through Kaizen Events 8. Mistake proofing, achieving zero defects 9. The human side of lean manufacturing 10. Kanban system Internet Sites 1. Laboratory Hardware: None Software: None Software Manual: None www.lean.org (accessed on 20th January 2012)

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MODULE ORGANISATION

Module Leader Name Room Telephone number E-mail Date and Time of Examination As per time table Sandeep. N B-504 080-49065555-2403 sandeepn@msrsas.org

Subject Quality and Approval Information Subject Quality Group / Subject Board Subject Assessment Board Shortened title Date of approval by MARP Mechanical and Manufacturing Engineering Postgraduate Engineering and Management Programmes LO November 2011

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