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THE COURSE
LEAN
OPERATION
MANAGEMENT
WELCOME TO THIS SESSION:
“CLIMATE SETTING & PRE COURSE ASSESSMENT”

FACILITATOR

SIR. CHRISTIAN T.G. TABLA – CIPS II & III, M.Sc, M.PSM, BBA, AA
FACILITATOR AMEU GRADUATE PROGRAM
CELL:O886-525747/0770525747
E-mail:libtusi6@yahoolcom
ctabla@ame.edu.lr
THE COURSE LEAN OPERATION MANAGEMENT

 IT’S 48 CREDIT HOURS

 RUNS THREE TIMES A WEEK
 MONDAY, TUESDAY AND WEDNESDAY
 TIME 5:00PM – 9:00PM (4 HOURS DAILY)
 COMPRISING ONE HEALTH BREAK DAILY
 CLIMATE SETTING.

WE LIKE TO WELCOME
YOU TO THE COURSE
LEAN OPERATION
MANAGEMENT
“ THE SUPPLY CHAIN PROFESSION”
 PERSONAL INTRODUCTION
EACH PARTICIPANT WILL FOLLOW THIS FORMAT:

1. CALL YOUR FULL NAME

2. STATTE YOUR QUALIFICATION(S)
3. STATE YOUR SOCIAL STATUS
4. STATE WHAT DO YOU DO FOR LIVING
5. -SECTOR OF EMPLOYMENT?
6. -YOUR ROLE?
-WORK EXPERIENCE?
-REASON(S) FOR DOING THIS COURSE?
5. STATE YOUR HOBBIT(S)
PARTICIPANTS EXPECTATIONS FOR THE
COURSE LOM
AS PARTICIPANTS YOU NOW HAVE THE OPPORTUNITY TO AT
LEASE STATE UP TO TEN EXPECTATIONS FOR THE COURSE LOM:
1. LOOKING FORWARD TO AN INTERACTIVE CLASS
2. WE WANT TO UNDERSTAND THE CONCEPT OF LEAN
OPERATION MANAGEMENT.
3. WE EXPECT FLEXIBILITY OF THE FACILITATOR
4. WE WANT THE BEST AND MOST OUTOF LEAN OPERATION
MANAGEMENT.
5. WE WANT TO GET NEW IDEOLOGY OF THE COURSE.
6. THE FACILITATOR SHOULD BE ON TOP OF THE SUBJECT
MATTER.
7. WE LOOK FORWARD TO HAVING CLEAR UNDERSTANDING OF
THE SUBJECT MATTER.
 SETTING GROUND RULES:
YOU AS PARTICIPANTS AND THE FACILITATOR WILL NOW SET THOSE GROUND RULES THAT WILL
GOVERN THE CLASS FOR THE DURATION OF THE COURSE LOM.
1. CLASS STARTS AT5:20.
2. THE CLASS WILL HAVE 2 HEALTH BREAKS WHICH WILL BE DETERMINED BY THE FACILITATOR.
3. ALL PARTICIPANTS SHOULD ALLOW THEIR COLLEAGUES TO SPEAK/EXPRESS THEMSELVES WITHOUT
INTERRUPTIONS.
4. ALL PHONES WILL BE PUT ON SILENT DURING CLASS TIME, AND YOU ARE ALLOW TO WALK OUTSIDE
TO TAKE AN IMPORTANT CALL.
5. WHERE THERE IS A POP TEST, REGULAR TEST OR FINAL EXAM, ALL PHONES WILL BE PUT OFF AND
AWAY FROM YOUR PERSON.
6. IF YOU AS A PARTICIPANT IS HAVING ANY PERSONAL ISSUE (S), THAT WILL NOT ALLOW YOU TO COME
TO SCHOOL, PLEASE TEXT DIRECTLY TO YOUR FACILITATOR ON 0770525747/0886525747, STATE YOUR
FULL NAME, ID NUMBER AND STATE YOUR PROBLEM.
7. IF YOU MISSED A TEST, MAKE SURE TO TAKE YOUR MAKE-UP BEFORE FINAL EXAM
8. EVERY MONDAY MALE PARTICIPANTS ARE REQUIRE TO WEAR ONE OF THE FOLLOWING
CORPORATE- DIPLOMATIC SUITS “BLACK, NAVY BLUE, GRAY OR ASH-GRAY” “WHITE, SKY
BLUE, ROYAL BLUE OR BLACK SHITES”
9. EVERY MONDAY FEMALE PARTICIPANTS ARE REQUIRE TO WEAR ONE OF THE
FOLLOWING CORPORATE- DIPLOMATIC SUITS –SKIRT, TROUSERS COATS, OR DRESSES
“BLACK, NAVY BLUE, GRAY OR ASH-GRAY”
10. ON THE DAY OF FINAL EXAM ALL PARTICIPANTS ARE TO BE FULLY ATIRED IN ANY OF
THE ABOVE AS A REQUIREMENT TO TAKE THE EXAM.
 CLASS STRUCTURE:

THE CLASS WILL BE DIVIDED INTO STANDING

WORKING GROUPS WITH EACH HAVING A
LEADER.
THE LEADER OF EACH GROUP SHALL BE
RESPONSIBLE FOR HIS/HER GROUP’S
ACCOUNTABILITY
THE CLASS COLLECTIVELY SHALL ELECT A
LEADER.
 CLASS STRUCTURE:
GROUP I GROUP II GROUP III GROUP IV

JOSHUA L. HOWARD GIFTY A. DALAMO EMMANUEL PORKA DEBORAH I DEEN

WOODROW MENTAR EZEKIE WEAH CLINTON KPAZEH MYKE MARTIN

NICHLASB. DOE MELVIN WEAH PRINCE JAHHAH KENNEDY HARRIS

DASH BARCHUE NAPOLEON LOLIN ZEKO G. MEAKA FRANCIS BOIMA

GBIELOR KOLLIE MIATTA JARBO

0886426787 088641225 0775050758

THE COURSE QUALITY MANAGEMENT
THE COURSE QM CONTAINS EIGHT MODULES:

TOPIC O: CLIMATE SETTING

TOPIC I:GENERAL INTRODUCTION LOM
TOPIC II: IMPLEMENTING LOM
TOPIC III: EXTERNAL LOM
TOPIC IV: EXTERNAL LOM (2)
TOPIC V: LOM VALUE ANALYSIS
TOPIC VI: PLUS ADDITIONAL MODULES
 THE COURSE LEARNING OBJECTIVES

IT IS HOPE THAT AT THE END OF THIS COURSE THAT:

PARTICIPANTS SHOULD KNOW THE CLEAR
UNDERSTANDING OF LEAN OPERATION MANAGEMENT
PARTICIPANTS SHOULD HAVE THE ABILITY IMPLANT
LEAN OPERATION MANAGEMENT (LOM ) PHILOSOPHY
WITH IN THEIR ORGANIZATIONS.
PARTICIPANTS BEING TOTALLY CONSCIOUS OF THE
IMPORTANCE OF LEAN WITH RESPECT TO ELIMINATING
WASTE
MOREOVER, PARTICIPANTS SHOULD BE ABLE TO
SUGGEST MEASURES AND PLANNED FOR CONTINUOUS
IMPROVEMENT IN ORGANIZATIONS.
 MODE OF COURSE DELIVERY
ANDRAGOGY(ADULT LEARNING - HANDS ON)
A COMBINATION OF METHODS WILL BE USED IN THE
DELIVERY OF THE COURSE:
THIS ENCOMPRISESES REGULAR POWERPOIMT LECTURES
PRESENTATION,
WRITING ON THE FLIP CHART,
PARTICIPATORY CLASS DISCUSSIONS WHICH WILL AFFORD
PARTICIPANTS TO SHARE EXPERIENCE AND LEARN FROM
EACH OTHER,
WHILE QUESTIONS AND ANSWERS WILL BE ADDRESSED.
FIELD ASSINGMENTS (HANDS ON APPROACH)
THERE WILL BE CONTINOUS ASSESSMENTS
LEAN OPERATION MANAGEMENT IS HIGHLY SENSITIVE

LEAN IS THE SIMI NERVES OF BUSINESSES SUCH

AS:

SERVICE PROVIDER
PRODUCTION
MANUFACTURING
HISTORY AND BACKGROUND
LEAN OPERATIONS AND MANAGEMENT

WHEN DID IT START AND WHERE?

THE FIRST PERSON TO TRULY INTEGRATE AN

ENTIRE PRODUCTION PROCESS WAS HENRY FORD.

AT HIGHLAND PARK, MI, IN 1913, HE MARRIED

CONSISTENTLY INTERCHANGEABLE PARTS WITH
STANDARD WORK AND MOVING CONVEYANCE TO
CREATE WHAT HE CALLED FLOW PRODUCTION.
HISTORY AND BACKGROUND
LEAN OPERATIONS AND MANAGEMENT

WHAT MOTIVATED HIM?

 HE HATED WASTE
 HE WANTED TO CORRECT OPERATIONAL
INEFFICIENCIES
 HE WANTED TO MAKE THE BEST POSSIBLE PRODUCTS
 HE WANTED PEOPLE TO WORK SMARTER AND NOT
HARDER

NOTE: BY DOING THE AFOREMENTIONED, FORD

TECHNICALLY INVENTED THE “PRINCIPLES OF LEAN”…..
HISTORY AND BACKGROUND
LEAN OPERATIONS AND MANAGEMENT

WHAT DID HE DO?

HE LINED UP FABRICATION STEPS IN PROCESS SEQUENCE

WHEREVER POSSIBLE USING SPECIAL-PURPOSE MACHINES AND
GO/NO-GO GAUGES TO FABRICATE AND ASSEMBLE THE
COMPONENTS GOING INTO THE VEHICLE WITHIN A FEW MINUTES,
AND DELIVER PERFECTLY FITTING COMPONENTS DIRECTLY TO
LINE-SIDE.

NOTE: THIS WAS TRULY A REVOLUTIONARY DEPARTURE FROM THE

SHOP PRACTICES OF THE AMERICAN SYSTEM THAT CONSISTED OF
GENERAL-PURPOSE MACHINES GROUPED BY PROCESS, WHICH
MADE PARTS THAT EVENTUALLY FOUND THEIR WAY INTO
FINISHED PRODUCTS AFTER A GOOD BIT OF TINKERING (FITTING)
IN SUBASSEMBLY AND FINAL ASSEMBLY.
HISTORY AND BACKGROUND
LEAN OPERATIONS AND MANAGEMENT

WAS IT A PANANCEA?
WHILST FORD CREATED TECHNIQUES THAT LED TO LEAN
METHODOLOGIES, THE ONE AREA HE DID NOT ACCOUNT FOR
WAS VARIATION. HIS PROCESSES, WHILE REVOLUTIONARY, DID
NOT ALLOW FOR THE TYPES OF VARIATIONS THAT MODERN
BUSINESSES REQUIRE.

FOR EXAMPLE, THE EMPLOYEE WHO ASSEMBLED THE BUMPER

FOR THE CAR DID SO THE SAME WAY, EVERY DAY, ONCE FORD
DETERMINED THE BEST WAY TO DO IT.

IN SHORT, HE WAS GREAT AT MAKING A MODEL T. BUT WHEN

PEOPLE WANTED SOMETHING OTHER THAN A MODEL, THERE
WERE CHALLENGES.
HISTORY AND BACKGROUND
LEAN OPERATIONS AND MANAGEMENT

THE BIRTH OF THE TOYOTA PRODUCTION SYSTEM

ABOUT 25 YEARS LATER, KIICHIRO TOYOTA AND OTHERS

AT TOYOTA REVISED MUCH OF FORD’S THINKING AND
DEVELOPED THE TOYOTA PRODUCTION SYSTEM, WHICH
FOCUSED ON MATCHING MACHINES TO THE WORKFLOW,
QUICK SETUPS AND MACHINE CHANGE-OVERS FOR
VARIOUS PRODUCTS AND WASTE ELIMINATION.
HISTORY AND BACKGROUND
LEAN OPERATIONS AND MANAGEMENT

WHEN DID THE LEAN PHILOSOPHY CAME TO THE ATTENTION OF THE

WESTERN WORLD?

 THE TERM LEAN WAS COINED BY JOHN KRAFCIK IN THE LATE 80‟S
(LEAN ENTERPRISE INSTITUTE, 2009), BUT THE PHILOSOPHY
CAME TO THE WESTERN WORLD’S ATTENTION ALREADY IN THE
BEGINNING OF THE 80‟S AS THE AUTOMOBILE INDUSTRY SUFFERED
BY THE COMPETITION FROM JAPAN WITH LOW PRICES AND
EXCELLENT QUALITY (LIKER, 2004).

 TRADE BARRIERS AND OTHER IMPEDIMENTS WERE SET UP

BEFORE IT WAS REALIZED THAT TOYOTA AND THEIR PRODUCTION
SYSTEM WAS THE NEW GUIDELINE TO FOLLOW FOR IMPROVED
QUALITY, PRODUCTIVITY AND FLEXIBILITY (WOMACK ET AL., 2007).
PRINCIPLES OF LEAN PHILOSOPHY
LEAN OPERATIONS AND MANAGEMENT

WHAT ARE THE PRINCIPLES OF LEAN PHILOSOPHY?

THE FIVE-STEP THOUGHT PROCESS FOR GUIDING THE IMPLEMENTATION OF LEAN

TECHNIQUES IS EASY TO REMEMBER, BUT NOT ALWAYS EASY TO ACHIEVE:

 SPECIFY VALUE FROM THE STANDPOINT OF THE END CUSTOMER BY PRODUCT FAMILY.
 IDENTIFY ALL THE STEPS IN THE VALUE STREAM FOR EACH PRODUCT FAMILY,
ELIMINATING WHENEVER POSSIBLE THOSE STEPS THAT DO NOT CREATE VALUE.
 MAKE THE VALUE-CREATING STEPS OCCUR IN TIGHT SEQUENCE SO THE PRODUCT
WILL FLOW SMOOTHLY TOWARD THE CUSTOMER.
 AS FLOW IS INTRODUCED, LET CUSTOMERS PULL VALUE FROM THE NEXT UPSTREAM
ACTIVITY.
 AS VALUE IS SPECIFIED, VALUE STREAMS ARE IDENTIFIED, WASTED STEPS ARE
REMOVED, AND FLOW AND PULL ARE INTRODUCED, BEGIN THE PROCESS AGAIN AND
CONTINUE IT UNTIL A STATE OF PERFECTION IS REACHED IN WHICH PERFECT VALUE IS
CREATED WITH NO WASTE.
 LEAN IS ASSOCIATED WITH QUALITY MANAGEMENT?

 LEAN PRODUCTION IS AN APPROACH TO MANAGEMENT THAT FOCUSES ON CUTTING OUT

WASTE, WHILST ENSURING QUALITY. THIS APPROACH CAN BE APPLIED TO ALL ASPECTS OF A
BUSINESS – FROM DESIGN, THROUGH PRODUCTION TO DISTRIBUTION.
 QUALITY MANAGEMENT ENSURES THAT AN ORGANIZATION, PRODUCTS OR
SERVICES ARE CONSISTENT.

 QUALITY HAS FOUR MAIN COMPONENTS:

o QUALITY PLANNING,
o QUALITY ASSURANCE,
o QUALITY CONTROL, AND
o QUALITY IMPROVEMENT

 LEAN/QUALITY MANAGEMENT IS FOCUSED NOT ONLY ON PRODUCT AND

SERVICE QUALITY, BUT ALSO ON THE MEANS TO ACHIEVE IT.

 LEAN/QUALITY MANAGEMENT, THEREFORE, USES QUALITY ASSURANCE AND

CONTROL OF PROCESSES AS WELL AS PRODUCTS TO ACHIEVE MORE
CONSISTENT QUALITY THEREBY ELIMINATING WASTE.
 COURSE EVALUATION
The Course evaluations will be marked and scored in accordance with those designated
Grades/Weights by the AMEU’s Graduate Program.

NO METHODS CRITERIA WEIGHTING

1 Attendance & Class participation,
2 Individual Homework
3 Syndicate/Groups Assignments &
presentations.
Evaluates class participation, contribution to
topics discussion, teamwork, work exposure,
innovation, homework and critical
evaluation.

4 Pop Test Theoretical- Practical part

Theoretical and Theoretical- practical and/or
5 Test problems knowledge will be evaluated
6 Individual written exam
100%
NO METHODS CRITERIA WEIGHTING

1 Attendance & Class participation, Evaluates class participation, contribution to 5 PTS

topics discussion, teamwork, work exposure,
innovation, homework and critical
2 Assignments 10 PTS
evaluation.
3 Individual Term Paper 10 PTS

4 Groups Term Paper & Presentations. 15 PTS

5 Pop Test Theoretical- Practical part

Theoretical and Theoretical- practical and/or
problems knowledge will be evaluated
20 PTS
6 Test

7 Individual Written Exam 40 PTS

100%
 I WILL NOW TAKE YOUR
QUESTIONS
AND
THEN WE DISCUSS
THE END !!!!!!!!!!!!!!!!

THANKS
 INDIVIDUAL PRESENTATION:
BRING GREETINGS
SELF INTRODUCTION
PRESENT A SYNOPSIS OF YOUR WORK
PRESENT YOUR FINDINGS
PRESENT YOUR REMEDIES
PASS YOUR WORK ON TO YOUR FACULTY FOR
REVIEW AND YOUR CROSS EXAMINATION
 GROUPS’PRESENTATION:
BRING GREETINGS
 INTRODUCTION SELF
PRESENT A SYNOPSIS OF YOUR GROUP’S WORK
PRESENT YOUR FINDINGS
PRESENT YOUR REMEDIES
PASS YOUR WORK ON TO YOUR FACULTY FOR
REVIEW AND YOUR CROSS EXAMINATION OF
MEMBERS.