Dalhousie University

IENG3320: Analysis and Design of Product

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Professor: Colleen Dewis

Name: Roberto Mendez

ID: B00909255

Due Date: August 1st, 2022

1. Group 4: Poka Yoke

a) What did they present?

They presented Poka-Yoke which is a method that looks for errors to achieve zero defects
when a production process is done. The meaning of Poka-Yoke is mistake proofing or
error proofing

b) How does it work (key points)?

It is related to lean manufacturing and 6-sigma to make sure that production processes
produce as fewer errors as possible. This method is also focused on reducing human
errors, which reduces the chances of misunderstandings.
The way how Poka-Yoke reduces errors is the following:
 Elimination: Getting rid of the step that causes errors.
 Prevention: Change the products to avoid mistakes.
 Replacement: Removing the step and replacing it with a new one.
 Facilitation: Making the right action less complex than the error.
 Detection: Finding the error before further steps are processed.
 Mitigation: Action to minimize the consequences of the errors.

c) What is the key takeaway message about how this relates to class material?
It is an approach that can be utilized in future courses or future coop terms. It is important
to mention that this method was developed by an industrial engineer in the 60s. Also, this
tool might be used for some of the labs we had for the class to reduce the number of errors
during the process.

d) Where is somewhere this may be useful in the industry?

All industries that carry out manufacturing processes must apply this technique because
they can prevent errors and potential accidents. Some of the errors can lead the expensive
consequences, therefore companies and industries can save a lot of money by applying
Poka-Yoke

e) Why did this title interest you?

It was an interesting name, I have never seen any process with a similar name or
pronunciation

2. Group 21: Theory of Constraints

a) What did they present?
They presented the theory of constraints, which is a useful topic that can be related to any
assembly line process, and it can fit in the course material as a method to improve
productivity in a facility or industry.
b) How does it work (key points)?
The methodology followed by this process is composed of several elements:
 The five focusing steps:
 Identify: Find the current constraint in the process
 Exploit: Find manners to improve the constraints
 Subordinate and Synchronize: Re-evaluates other tasks to make sure that
they are related to the constraint being focused on
 Elevate: Increase the actions to solve the constraint
 Repeat: Move to the next constraint.
 The thinking processes: This process proposes some questions to have a deeper
understanding of the constraint’s cause and effect relationship. Some questions that
can be asked are:
 What needs to be changed?
 What should it be changed to?
 What actions will cause the change?
 Throughput accounting: Method to improve the distortions found in accounting

c) What is the key takeaway message about how this relates to class material?
This is related to class material because it mentions that the theory of constraints can be
applied in any assembly line process to make individual tasks better and more effective.
Also, this is a method that is focused on improving production processes, which is a topic
that has been covered in the course.

d) Where is somewhere this may be useful in the industry?

This methodology can be applied to any process that is looking for improvements in
processes’ efficiencies. It can also be utilized in any assembly line process

e) Why did this title interest you?

I did not see this topic as part of the course material. And I find it interesting to learn
something new that I have not heard anything about before.

3. Megan Greenwald, Nicholas Fallows, Yassine Yassine, and MJ Funsho’s group

a) What did they present?

They presented lean manufacturing, which consists of some techniques that will allow to
decrease and get rid of waste.
b) How does it work (key points)?
In an assembly line, the main idea of lean manufacturing is to distribute different bins for
each workstation, and each one will just contain the necessary number of materials for the
following assembly process. Lean manufacturing is focused on reducing the amount of
waste to reach a target as efficiently as possible.

c) What is the key takeaway message about how this relates to class material?
The process is useful to apply in the labs we have worked on so far in a way that it is
possible to improve the results that were obtained, and there is a chance to improve the
assembly line created for lab one. It is also related to managing line failures and material
required planning which are key concepts of the course.

d) Where is somewhere this may be useful in the industry?

It will be useful in any assembly line process. The main goals of lean manufacturing will
be to provide bins for all workstations, designate a member of the staff to stock all bins,
and have team-focused workstations for better defect management.
Lean manufacturing can also be applied in minimal staffing or overstaffing, improper shift
schedules, and complex instructions.

e) Why did this title interest you?

It seems an interesting topic to apply in the assignments that have taken place so far, or in
any future co-op term. It is also interesting because it is a process that is utilized by many
companies; therefore, it is useful to learn the main idea of lean manufacturing.

4. Lindsay Cormier, Amelia Lane, and Skylar Spafford’s group

a) What did they present?

They presented six sigma, which is a process focused on reducing defaults, increasing
earnings, and improving product quality and services

b) How does it work (key points)?

In general terms, six sigma can be defined as the DMAIC if it is aiming to improve an
existing product. The meaning of this acronym is the following:
o Define the problem
o Measure the problem
o Analyze the main causes of the problem
o Improve the solution
o Control and keep the solution
c) What is the key takeaway message about how this relates to class material?
The methods that have been covered in class can be related to six sigma depending on the
type of problem that needs to be solved. One way in which six sigma can be used is that it
is possible to correct or improve some issues that cause a delay in a line balancing process,
therefore, the line balancing carried out in design lab 1 could be improved.

d) Where is somewhere this may be useful in the industry?

This method can be used in industries of any size. Some of the main advantages of
applying this method are reducing waste and cutting down on the unused time for complex
tasks. Also, six sigma is useful to increase customer ratings, improve service time, and
design new processes. Big and small companies can take advantage of the benefits
obtained by applying six sigma to any process.

e) Why did this title interest you?

It is a method that is used by many companies and industries, therefore, it is important to
understand the main idea of the six sigma process.

5. Erwin Diallo, Adrien Boudreau, and Ronish Gobin’s group

a) What did they present?

They presented Just-in-Time, which is a process that has a lot of impact on any type of
production system.

b) How does it work (key points)?

The JIT process consists of the following 5 steps:
 The customer places an order.
 Suppliers are contacted.
 Suppliers are responsible for delivering materials or parts.
 The product is built.
 The product is delivered to the customer.

c) What is the key takeaway message about how this relates to class material?
It is related to the course because it can be applied to topics such as line balancing, job
scheduling, and inventory control. Therefore, this process might be useful for some future
courses and coop terms.
d) Where is somewhere this may be useful in the industry?
According to one of the examples provided by the group, this approach can be used in
large industries such as Toyota. The main goals of the Just-in-time process are keeping the
highest product quality, the lowest cost, and the shortest lead time. The just-in-time
process is responsible for setting up the order, obtaining manufacturing materials,
 producing parts, assembling, and delivering the product to the customers. By delivering
the product when it is finished, holding costs are reduced, and there is more space to keep
producing vehicles in this case.

e) Why did this title interest you?

It sounds interesting because the title implies that is focused on reducing waiting times,
and making processes faster.

6. Manika Sahu, Luca Salvatore, Abdullah Nimer, and Adithya Rajeev’s group

a) What did they present?

They presented Industry 4.0 which can also be recognized as the fourth industrial
revolution.

b) How does it work (key points)?

In the future, the transition to using Industry 4.0 technology will allow companies and
industries to have improved efficiency by using smart technologies. These technologies
will help managers have a deeper conception of how the systems work. Some of the
advantages of this process are that it will allow companies to adapt supply chains, increase
demands, and provide analyses at the moment.
c) What is the key takeaway message about how this relates to class material?
This process can be applied to the first designed lab that was carried out by the class.
Using tools with better technology instead of simple screwdrivers will allow processes to
finish faster. This process can be used to improve the assembly line in order to reduce
time, cut down on the number of mistakes, and improve productivity.
d) Where is somewhere this may be useful in the industry?
This process can be utilized in any industry that is looking to improve its technology in
order to make processes faster and more efficient. Also, by using industry 4.0
technologies, it is easier to keep track of all tasks, materials, and staff in the entire facility
e) Why did this title interest you?
It was the only group that talk about Industry 4.0, and I find it interesting to understand
what new technologies will be used in the future.
7. Group 7: 5s Systems

a) What did they present?

They present the 5s system which is a manufacturing technique that improves productivity
and cut down on waste in industries.
b) How does it work (key points)?
The five steps that composed the 5s system are the following:

 Sort: This is focused on removing material that is not needed.

 Set in order: organizes materials to have easier access to them.
 Shine: It is focused on cleaning the work area.
 Standardize: Focused on standardizing the first 3 steps daily to keep the industry in
competent conditions.
 Sustain: Focused on repeating the first four steps.

c) What is the key takeaway message about how this relates to class material?
The 5s system can be applied to the assembly line that was built for the lab in order to
make it quicker and more effective. Also, the five steps can be used in any future course or
coop term job in order to increase safety, minimize wasted time, and lower costs.
d) Where is somewhere this may be useful in the industry?
This process can be utilized in any industry to increase productivity, and minimize waste.
Some of the industries where this process can be applied are health care facilities, office
jobs, homemakers, restaurants, and manufacturing facilities. The 5s system will allow all
these places to produce better product quality and have greater safety.
e) Why did this title interest you?
This was the only group covering 5s systems, which is an important process that is
focused on quality and cleaning in work areas.

8. Group 17 Value Stream Mapping

a) What did they present?

They presented Value Stream Mapping which is a process of visually mapping
information to prepare a future state map in order to improve methods and performance.
b) How does it work (key points)?
Some keys to the methodology of this process are data collection, mapping current and
future states, and improving the system. On the other hand, the steps to create a value
stream mapping are the following:
 Create an outline of the process
 Depict the flow of information and material
 Add timeline and calculations
 Include process data

c) What is the key takeaway message about how this relates to class material?
This process is related to the class material because it can be applied to production lines,
and scheduling processes. The process can be utilized when a process is experiencing a
bottleneck in its production.
d) Where is somewhere this may be useful in the industry?
This method may be useful in any company looking to improve its results and
productivity. As shown by the group, this process can be utilized to improve any assembly
line, therefore any industry interested in improving its lines can apply this method.
e) Why did this title interest you?
This was the only group that talked about Value Stream Mapping. Besides, the topic
reflects the way how cycle times, amount of inventories, and manpower can be improved
in order to be more efficient.
9. Debby Esho, Ceren Erturk, Georgio Lawen, Sawda Ramisa’s group

a) What did they present?

They presented the lean manufacturing process, which is a process focused on maximizing
productivity and minimizing waste
b) How does it work (key points)?
Some of the advantages of lean manufacturing are the following:

 Eliminates waste in order to reduce costs, and meet deadlines

 Improves quality to maintain competitiveness among other companies
 Reduces costs to make more profits.
 Reduces processing times which generates a loss of money.
c) What is the key takeaway message about how this relates to class material?

It is related to the course because lean manufacturing is focused on productivity and waste
management. It is also related because it looks for some way to make a line more efficient
and increase the amount of work done in a certain time.

d) Where is somewhere this may be useful in the industry?

As mentioned by the group, this process can be used in large companies such as Nike.
Applying lean manufacturing will enable the company to reduce lead times, and improve
the supply chain in order to prevent mistakes.

e) Why did this title interest you?

The title was interesting because it is a process that improves productivity in industries,
and enhances communication among the workers.

10. Group 16: The Six-Sigma Methodology

a) What did they present?

They presented the six-sigma methodology which is a process implemented in
manufacturing and service industries.
b) How does it work (key points)?
The six-sigma methodology consists of 5 steps, and they can be represented by the
acronym DMAIC:
 Define customer requirements
 Measure current performance
 Analyze, prioritize and implement improvements
 Identify processes and key customers
 Expand and integrate the six sigma system

c) What is the key takeaway message about how this relates to class material?
It is related to the course because the Six-Sigma methodology is built around analyzing
and testing processes in order to look for some ways to make them better and get more
efficient results. In this case, Six-Sigma can be applied to some of the topics covered in
class such as job scheduling, and line balancing.

d) Where is somewhere this may be useful in the industry?

This process can be applied to any industry in order to develop well-integrated processes.
It is important to mention this method has a lot of experience in correcting mistakes and
 improving services. Also, this process helps businesses understand the importance of
meeting customers’ expectations.

e) Why did this title interest you?

What I found interesting about this title was the importance of learning the main goals of
six-sigma because it can be applied in many areas and industries.