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MSE 597 Course Syllabus

Purdue University, School of Materials Engineering

Lean Manufacturing Spring 2017

Lecture: MWF 8:30-9:20; Wang 2579

Instructors
Prof. Chris Owen, ARMS 2225, 765-421-9096 (cell), owen12@purdue.edu (email)
Office hours TBD (or whenever you see the door open)
T.A. TBD

Course Description
Lean Manufacturing is about creating value. The Lean process starts with creating value for the
ultimate customer which requires providing the right product at the right time for the specified
price. While all manufacturing attempts to do this, what makes Lean Manufacturing distinct is
the relentless pursuit and elimination of waste. Students will learn the concepts and tools of
Lean which include types of waste, visual management, 5S, value stream mapping, A3, & flow.

Enduring Understandings
1. To understand the distinction between Mass Production and Lean Manufacturing and to
analyze a facilitys progress in the transition from Mass to Lean.
2. Value Stream Mapping. The intent is to provide lean thinkers the most valuable tool
they will need to make sustainable progress in the war against muda [waste]: the value
stream map. (Rother and Shook).

Learning Objectives
1. Articulate a case for Lean. Students will be able to present an argument on why Lean is
a superior environment to Mass.
2. Compare and contrast the culture, organizational structure and leadership in Mass and
Lean environments.
3. List and describe the Types of Waste and why waste elimination is a core component of
Lean Manufacturing.
4. List and describe lean functionality (i.e. quality, continuous flow, pull systems, 5S, Visual
Control, Kanban, etc).
5. Articulate why the Rules in Use were a breakthrough in understanding the Toyota
Production System.
6. Understand A3 thinking and draw an A3.
7. Students will demonstrate the ability to draw a Value Stream Map of an actual
manufacturing process.

Prerequisites
Junior or higher standing in Engineering or Science
Textbooks
(1) J.P. Womack, D.T. Jones, D. Roos, The Machine that Changed the World, Free Press,
1990 (2007 in paperback). ISBN-13: 978-0-7432-9979-4. The content is the same for
both printings.

(2) J.K. Liker, The Toyota Way, McGraw Hill, 2004. ISBN 0-007-139231-9

(3) M. Rother, J. Shook, Learning to See, Lean Enterprise Institute, 2009.


ISBN: 9978-0-9667843-0-5

Supplemental reading
Will be posted on Blackboard as needed.

Learning Environment
The research is clear that long-term learning takes place only when accompanied by
deliberate, distributed practice. To accomplish that end, this class is structured so that
subjects will be covered in a way to provide students opportunity to practice.

We expect that the student will:


1. Attend all classes or watch all videos. If you miss a class it is expected that you will watch
the video of the missed classed before attending the next.
Course Login ID Number 9999990882
Course MSE59700
The URL for distance students is https://engineering.purdue.edu/ProEd/current_student.
2. Read the assigned material before class. By coming prepared to class, students will be in a
better position to learn the content.
3. Do good work. Utilize this opportunity to do work that will be expected of you as a practicing
engineer.
4. Turn assignments in on time. If you will have a problem completing your work on time, then
you need to contact the instructor before the assignment is due to receive credit.
5. Short exercises will be provided to facilitate learning. It is expected that you will do the
assigned reading and complete the exercise before coming to class or watching the video.
6. Muddy Points are a blog in Blackboard. The intent is to provide a forum in which questions
can be posted and addressed. It is intended that everyone participate in at least asking if
not answering questions. The instructor will address Muddy Points at the beginning of the
next class period.
7. You will turn your cell phone off before class and not refer to it during class. I find it very
distracting to try to teach while you are playing with your phone.
8. You will only use your computer during class for class purposes.
9. Follow scholastic conduct policy:
http://www.purdue.edu/univregs/pages/stu_conduct/stu_regulations.html
10. Complete and submit a thoughtful online course evaluation.
You can expect that the instructors will:
1. Provide a supportive learning environment that fosters your success.
2. Create exercises, homework assignments and tests that approach real life problems and
situations (authentic performance tasks) faced by the practicing engineer.
3. Provide timely feedback on your work with the intent of facilitating your understanding of the
content.
4. Follow the syllabus.
5. Structure exams to predominantly address the Learning Objectives.
6. Review Muddy Points from the prior class at the start of the next class.
7. Every attempt will be made to post the lecture slides the morning of the class.
8. Make the video recordings available to both distance and on-campus students.
9. Honor and respect your interests.

How to approach this class:


1. You need to stay current with the lectures. Students have reported getting behind in
previous courses. As some of the most important content build on previous concepts, it is
important that you master one concept before being introduced to the next. This is the
deliberate, distributed practice. If you do not deliberately practice the concepts in sequence,
the probability of doing well in the course decreases significantly.
2. Read the material before the lecture. This will provide a foundation for the concept. By
having a foundation, the lecture will build on it and help to put it in context. You should not
expect to understand the concept if the first time that you are exposed to it is the lecture.
3. Complete the Exercises prior to the lecture. Exercises are provided for your benefit. They
are intended to stimulate your thinking and to provide clarity for the concept being covered.
Because the exercises are not graded, some students ignore them entirely. In doing so,
they miss an opportunity to practice and to learn.
4. Get help. Use the Muddy Points to get clarity on topics you want additional information on.
If not satisfied with answer, then visit, call, text, or email me for additional help. Again,
because of the sequential nature of the course, falling behind will likely result in the class
becoming a struggle.
5. Recognize the importance of the Learning Objectives. As shown in the attached Schedule,
the course will focus on the Learning Objectives. Homework and exams will be based on
the learning objectives. Make sure you understand the expectations for each learning
objective. This will be especially important when preparing for exams.
6. The case studies are designed to facilitate learning. The intent is for you to research the
topic and do sufficient work to learn the subject and be able to teach others. In preparing to
engage in the Wiki, ensure that you have identified the concepts in the course that are the
foundational concepts for the case study. Work with your team to ensure everyone can
address the topics that have been provided.

Course requirements and grading: This is a 500 level class that is designed to build on prior
learning. The intent is to synthesize content from earlier courses taken as an undergraduate.
Recognizing that some time may have lapsed and that some content may have been forgotten,
assessments and feedback will be provided. The purpose for these assessments is to provide
the student feedback on gaps in understanding. Students are expected to recognize gaps and
to seek help either from the instructor, on-line, or from other sources. By being clear about
course curricular priorities and learning expectations, the intent is that you, as the student, will
take an active role in learning and mastery of the content.

Final grades will be based on A>90%, 89%<B<80%, 79%<C<70%, etc. + and - will be
assigned as appropriate.
Your grade for the course will be determined by the following:
1. 20% of your grade will be earned by your participation in learning teams. Teams will be
established by the 4th class lecture. Teams will develop a Code of Cooperation. Three
times during the semester your team will be presented case studies that you are to work
together to solve. Your team will participate in a Blackboard Wiki to address the topics. At
the end of the case studies you will be expected to provide a peer assessment of your
teammates. If you do not turn in a peer review, then you will review 0% for the assignment.
Learning team grade will be 15% for the Code of Cooperation, 75% for the three case
studies, and 10% for the Peer Review.
2. 20% of your grade will be determined by the results of your homework. Five homework
assignments will be given throughout the course. These assignments will focus on the
Learning Objectives. As the Learning Objectives will be the basis of the exams, homework
is intended to provide feedback on the level of content understanding to enable students to
be better prepared for the exams.
3. 40% of your grade will be determined by two midterm exams. As the concepts covered in
the course serve to build an understanding of Lean, each exam builds on the information
covered earlier in the course. It is important that you understand the concepts. You should
ensure you understand the questions from previous exams as you prepare for the next one.
4. 20% of your grade will be determined by a comprehensive final exam.

Emergency Response
If we are notified of a Shelter in Place requirement for a tornado warning we will shelter
in the lowest level of this building away from windows and doors. Our preferred location
is the basement.
If we are notified of a Shelter in Place requirement for a hazardous materials release we
will shelter in our classroom shutting any open doors and windows.
If we are notified of a Shelter in Place requirement for a civil disturbance such as a
shooting we will shelter in a room that is securable preferably without windows. Our
preferred location is this classroom.
If we hear a fire alarm we will evacuate the building via the nearest stairway and proceed
to an assembly area at the Northwestern Parking Garage.
General Statement on Academic Dishonesty
Purdue University Regulations, Part 5, Section III-B-2-a describes the formal policies governing
academic dishonesty. Purdue prohibits "dishonesty in connection with any University activity.
Cheating, plagiarism, or knowingly furnishing false information to the University are examples of
dishonesty." A guide providing specific examples, tips, and consequences is available from the
Office of the Dean of Students at:

http://www.purdue.edu/odos/osrr/academicintegritybrochure.php .

As discussed in this brochure on Academic Integrity, there are many dishonest ways to gain an
advantage over another student in an assignment. The goal is not to list these here, but these
rules cover any assignment for which the instructor will assign a grade (homework, quizzes,
exams, laboratory reports, term paper, etc.). Rather, students should ask themselves this
question when working on all class assignments: If I use this information, will the completed
assignment represent only my efforts? If the answer is no, then dont do it. The test is simple.
For example, turning in a term paper obtained from a website does not represent your efforts.
Turning in copied homework from another student or solutions manual does not represent your
efforts either.

Consequences of Academic Dishonesty


The teaching staff for this course will diligently monitor academic dishonesty in all assignments.
Students found to engage in academic dishonesty are subject to discipline that includes a grade
of zero for the assignment in question and a permanent letter added to the students official file.
Two letters in a students file resulting from this class will result in a grade of F for the course
and in an automatic forwarding of the case to the Dean of Students.

Please note that current students who share prior solutions with students currently enrolled in
the course will also have a permanent letter added to their official files.
MSE 597 Lean Schedule

Wk Meeting Session Topics Reading Learning Assignment Due


# Objective
M Jan 9 1 Introduction
1 W Jan 11 2 The Lean Practitioner 1,2
F Jan 13 3 The Lean Context MCW Chap 1 1
LTS Foreward
M Jan 16 MLK, Jr. Holiday
2 W Jan 18 4 Mass Production Part 1 MCW Chap 2 1
F Jan 20 5 Mass Production Part 2 MCW Chap 2 1
M Jan 23 6 Lean Production MCW Chap 3 1
3 W Jan 25 7 Optimum batch size MCW Chap 3 2
F Jan 27 8 Running the Factory MCW Chap 4 2 Homework 1
M Jan 30 9 Lean Organization MCW Chap 4 2 Code of Cooperation
4 W Feb 1 10 Designing the Car MCW Chap 5 2 Case Study #1
F Feb 3 11 Suppliers and Customers MCW Chaps 6-7 2 Lean Design
M Feb 6 12 Decoding the DNA of TPS Supplemental 5
5 W Feb 8 13 Manufacturing as a strategy TW Chap 1 5
F Feb 10 14 Exam #1
M Feb 13 15 Toyota Background TW Chap 2 2
6 W Feb 15 16 Quality Foundation TW Chap 11 2
F Feb 17 17 Types of Waste TW Chap 3 3 Homework 2
M Feb 20 18 Eliminating Waste (Toast Video) 3
7 W Feb 22 19 Toyota Culture 1 TW Chap 7 2 Case Study #2
F Feb 24 20 Toyota Culture 2 TW Chap 7 2 NUMMI
M Feb 27 21 Continuous Flow TW Chap 8 4
8 W Mar 1 22 Pull Systems TW Chap 9 4
F Mar 3 23 Level out the workload TW Chap 10 4
M Mar 6 24 VSM Getting Started LTS Part 1 7
9 W Mar 8 25 VSM Current State 1 LTS Part 2 7
F Mar 9 26 VSM Current State 2 LTS Part 2 7 Homework 3
M Mar 13
10 W Mar 15 Spring Break
F Mar 17
M Mar 20 27 VSM AMP Video LTS Part 2 7
11 W Mar 22 28 VSM AMP Current State LTS Part 2 7
F Mar 24 29 Exam #2
M Mar 27 30 VSM Lean Value Stream LTS Part 3 7
12 W Mar 29 31 VSM Future State 1 LTS Part 4 7
F Mar 31 32 VSM Future State 2 LTS Part 4 7 Homework 4
M Apr 3 33 VSM Future State 3 LTS Part 4 7
13 W Apr 5 34 VSM Achieving the Future State LTS Part 5 7 Case Study #3
F Apr 7 35 Visual Factory TW Chap 13 4 AMP VSM
M Apr 10 36 A3 Current Condition Supplemental 6
14 W Apr 12 37 A3 Target Condition 6
F Apr 14 38 5S Part 1 Supplemental 4
M Apr 17 39 5S Part 2 4
15 W Apr 19 40 Standard Work 4
F Apr 21 41 The Right People Supplemental 2 Homework 5
M Apr 24 42 Jacques Vanier President Alcoa F&E 2,6
16 W Apr 26 43 Eliminating Waste 3
F Apr 28 44 Case Studies
17 May 1-6 Final Exam

Changes to this schedule will be announced in class and posted to Blackboard.