Thursday, July 21, 2022
Monday, May 23, 2022
Lean Management Micro Lesson Plan Batch 2021-22
ANDHRA
LOYOLA INSTITUTE OF ENGINEERING AND TECHNOLOGY
Department: MBA Subject:
LEAN MANAGEMENT Year/Semester: I Year /II Semester
Teacher : LAVANYA P B Academic Year: 2021-22
Course Objectives:
|
CO 1 |
To make the student learn the evolution
of Lean management and basic concepts of lean management. |
|
CO 2 |
The
students will be able to analyze various methodologies, tools and techniques
of Lean manufacturing and to create strategies for lean manufacturing in
different companies. |
|
CO 3 |
To
make the students apply lean methodologies, tools and techniques for building
standardization.
|
|
CO 4 |
To make the student apply Total
Productive Maintenance in improving effectiveness and analyze common layouts
of standardized work. |
|
CO 5 |
To make the student understand
lean culture, role of Quality circles and analyze the policy deployment of an
organization. |
Course Outcomes:
|
Factual |
Students will be able to understand
various types of production and concepts of lean production. |
|
Conceptual |
Students will exhibit a clear understanding
of various lean management concepts, tools and techniques used by
executives in business. |
|
Procedural |
Students will be able to exhibit
procedural knowledge in applying lean process. |
|
Applied |
Students will be able to analyze and
evaluate lean practices and will be able to create effective lean
management strategies. |
Text book References:
1. David
Magee, How Toyota Became # 1 Leadership Lessons from the world’s Greatest Car
Company, Penguin Speakers Bureau
2. Dale H.,
Besterfield , Carol, Besterfield, etal, Total Quality Management (TQM) 5e by
Pearson 2018.
3. Wisner,
Tom and Leong, Supply Chain Management- A Balanced Approach, Cengage Learning,
3rd Edition, 2017
4. N V S
Raju, Total Quality Management, Cengage Learning, 2014
5. Operations
Management, ICFAI Centre for Management Research, 2nd Edition, 2007
6. Stephen
Borris, Total Productive Maintenance proven strategies and Techniques to keep
equipment running at peak efficiency, Mc Graw Hills, e copy
E- Sources- You tube
videos
Acknowledgement-
The references used in this Micro lesson plan from textbooks, websites, blogs,
e-books and you tube videos are used only for academic purpose and they are the
intellectual property of the respective authors, publishers and developers, I duly
acknowledge and thank all of them.
Contents/Activities:
1
|
Factual: Factual knowledge consist basic
information about a particular subject or discipline that students must be
acquainted with. This may include the terminology and the specific details or
elements of a subject
|
·
Types of Production (Unit-1)
·
Lean Production (Unit-1)
·
Systems Thinking (Unit-1)
·
Waste Management (Unit-1)
·
JIT (Unit-2)
·
Kanban (Unit-2)
·
Jidoka (Unit-2)
·
Poka Yoke (Unit-2)
·
Kaizen (Unit-3)
·
Failure Mode Effect Analysis (FMEA) (Unit-3)
·
Quality Function Deployment (Unit-3)
·
Statistical Process Control (Unit-3)
·
Total Productive Maintenance (Unit-4)
·
Standardization (Unit-4)
·
Hoshin Kanri (Unit-5)
·
Lean Culture (Unit-5)
|
2
|
Conceptual: Conceptual knowledge consists of knowledge of, or understanding of concepts, principles, theories, models,
classifications, etc. We learn conceptual
knowledge through reading, viewing, listening, experiencing, or thoughtful,
reflective mental activity.
|
·
Principles of Mass, Craft and Lean Production (Unit-1)
·
Image of Toyota Production system (Unit-1)
·
Principles of Systems thinking (Unit-1)
·
Principles of JIT (Unit-2)
·
Principles of Kanban (Unit-2)
·
Principles of Jidoka (Unit-2)
·
Types of Heijunka (Unit-2)
·
Types of Pull system (Unit-2)
·
Types of Inspection systems (Unit-2)
·
Types of Poka Yoke (Unit-2)
·
Principles of Kaizen (Unit-3)
·
Philosophy and methodology of Six Sigma (Unit-3)
·
QFD principles and House of Quality (Unit-3)
·
FMEA types and methods (Unit-3)
·
Different types of Statistical Quality control (Unit-3)
·
5 s system (Unit-3)
·
Elements of standardized work (Unit-4)
·
Types of common charts (Unit-4)
·
Activities of TPM (Unit-4)
·
Structure of Quality circles (Unit-5)
·
Employee involvement methods (Unit-5)
·
Policy deployment stages (Unit-5)
|
3
|
Procedural: Procedural knowledge
is the knowledge exercised in the performance of some task.
|
·
Creating customer Focus through Lean system
(Unit-1)
·
Identifying various types of waste management
(Unit-1)
·
JIT process (Unit-2)
·
Calculating Kanban (Unit-2)
·
Calculating Heijunka using volume and product
(Unit-2)
·
Construction of VSM and metrics (Unit-2)
·
Implementation of Jidoka (Unit-2)
·
Calculation of control using various SPC methods
(Unit-3)
·
Construction of QFD (Unit-2)
·
Construction of FMEA (Unit-2)
·
Preparation of standardized work layouts (Unit-4)
·
Preparation of TPM, calculation of OEE (Unit-4)
·
Construction of X Matrix (Unit-5)
·
Practical Kaizen Training preparation (Unit-5)
·
Creating Lena culture (Unit-5)
|
4
|
Applied: Applied
knowledge is learning that is used in various situations and contexts.
|
·
Application of Muda, Mura and Muri in business
(Unit-1)
·
Using System thing for Decision Making (Unit-1)
·
Inventory management using JIT (Unit-2)
·
Application of Kanban for replenishment (Unit-2)
·
Analyzing Heijunka to meet Customer Demand
(Unit-2)
·
Construction of Future VSM, implementation plan (Unit-2)
·
Application of Jidoka- Poka Yoke, Andon,
Inspection methods, zone of control (Unit-2)
·
Building Six Sigma using DMAIC and DMADV (Unit-3)
·
Improving quality using Six Sigma, QFD, FMEA, SPC,
QC and 5 S (Unit-3)
·
Analyzing TPM (Unit-4)
·
Analysis of Standardized Work layouts (Unit-4)
·
Analysis of Hoshin Kanri (Unit-5)
·
Involving people in lean, culture adoption, PKT
implementation (Unit-5)
|
Schedule and Sequence:
Day
|
Topic
|
Objectives
|
Before Class-Videos, e-Books, Case Studies
|
In-Class-Activities, Quiz
|
Post-Class-Assignment, Discussion Forum
|
1
|
Introduction to production, production process
|
· To understand production
process
· To know types of production
process
· To understand image of TPS
· To use systems thinking for
decision making
· To apply waste management
|
TB 5 page numbers |
· Ice-Breaking
session on Industrial revolution · Introduction
to production process, production
function using PPT |
Discussion Forum |
2
|
Types of Production
|
TB 5 page numbers |
· Lecture
on types of Production using PPT · Eliciting
examples from students for different industries |
Self Study- Advantages and limitations of
each production type |
|
3
|
Mass Production |
TB 5 page numbers Video: https://www.youtube.com/watch?v=VstNwIywsKI&t=261s Source- Internet |
· Lecture
on Mass production characteristics using PPT · Discussion
on advantages and disadvantages of Mass Production |
Study of select company using mass
production |
|
4
|
Craft Production
|
TB 5 page numbers |
· Lecture
on Craft production characteristics using PPT · Discussion
on advantages and disadvantages of craft Production |
Study of select company using craft
production |
|
5
|
Lean Production Introduction
|
TB 1 page numbers 1-24 Video: https://www.youtube.com/watch?v=VstNwIywsKI Source- Internet |
· Lecture
on Lean production characteristics using PPT · Video of
TPS |
Discussion Forum – characteristics of lean
production and Study introduction – The Toyota Way Text book |
|
6
|
Evolution of Lean Production |
TB 1 page numbers 1-24 Video: https://www.youtube.com/watch?v=wk-Mz_4Rzx0 Source- Internet |
· Discussion
on Video of TPS · Lecture
on Timeline of TPS using PPT |
Discussion Forum |
|
7
|
Image of TPS – Pillars
|
TB 1 page numbers 25-45, 213-214 Video: https://www.youtube.com/watch?v=OfOrINGL6MA Source- Internet |
· Lecture
on Toyota House pillars using PPT · Paired
work on identifying companies using Lean production |
Draw Toyota production house and briefly explain |
|
8
|
Image of TPS – Foundation
|
TB 1 page numbers 25-45, 213-214 |
· Foundation
of TPS using PPT · Discussion
about Toyota production house and Doubts clarification |
Discussion Forum |
|
9
|
Systems Thinking -1
|
TB 1 page numbers 103-116 |
· Self
Activity by students on day plan and time taken for various decisions of Life · Introduction
to Systems thinking-1 using PPT |
Write the works that you do with Systems Thinking 1 |
|
10
|
System thinking -2
|
TB 1 page numbers 103-116 |
· Lecture
Systems Thnking-2 using PPT · Trios
activities for students to distinguish between Systems Thinking1 & 2 |
Discussion Forum Write the works that you do with Systems Thinking 2 |
|
11
|
Principles of Lean Management-
Customer Focus
|
TB 1 page numbers 85-102, 117-130 |
· Lecture
on principles of lean management using PPT · Group
discussion on customer centric approach |
Self study of Customer focus- a select company |
|
12
|
Waste Management
|
TB 1 page numbers 59-71 |
· Lecture
on Waste Management using PPT · Doubt
clarification |
Self study – Write how you manage your waste |
|
13
|
Just In Time: Introduction JIT principles and JIT
system
|
· To understand main pillars of
TPS – JIT, Jidoka, Kanban, Heijunka, Jidoka
· To apply VSM, Kanban, Heijunka,
|
TB 3 page numbers 137-293 Video: https://www.youtube.com/watch?v=OXVi7dOF3jU&vl=en Source- Internet |
· Discussion
on case of Amul Milk Production · Lecture
on introduction to JIT using PPT |
Select and study alteast one company using JIT |
14
|
Kanban- Types of Kanban, Rules
|
https://kanbanize.com/kanban-resources/getting-started/what-is-kanban Source- Internet |
· Lecture
on Kanban, rules and types of Kanban using PPT · Small
exercise on using Kanban |
Discussion Forum |
|
15
|
Expanded role of Conveyance
|
https://kanbanize.com/kanban-resources/getting-started/what-is-kanban Source-
Internet |
· Lecture
on expanded role of conveyance using PPT · Identifying
Number of Kanban required |
Discussion Forum |
|
16
|
Heijunka – Production leveling |
https://www.isixsigma.com/methodology/lean-methodology/heijunka-the-art-of-leveling-production/ Source-
Internet |
· Lecture
on Heijunka using PPT · Exercise
on calculating production leveling |
Develop a Heijunka Box for single and multiple products |
|
17
|
Three Types of Pull System |
https://www.lean.org/lexicon/pull-production Source-
Internet |
· Lecture
on Three Types of pull systems using PPT · Doubt
clarification |
Observe the pull system of a super market and compare it with milk booth |
|
18
|
Three Types of Pull Systems |
https://www.lean.org/lexicon/pull-production Source- Internet |
· Lecture
on Three Types of pull systems using PPT ·
Comparison of Three types of pull in Trios |
Discussion Forum – observation of your select company pull system |
|
19
|
Value Stream Mapping Introduction |
https://kanbanize.com/lean-management/value-waste/value-stream-mapping Video:
https://www.youtube.com/watch?v=fkk0hkunfcE
all series Source- Internet |
· Introduction to VSM using PPT · Discussion on various metrics used in VSM |
Draw the basic template of VSM |
|
20
|
Construction of Current VSM |
https://kanbanize.com/lean-management/value-waste/value-stream-mapping Source- Internet |
·
Construction of
VSM by students using hints in trios |
Construct current VSM of a select company and identify VA, NVA and Kaizen areas |
|
21
|
Calculation of metrics for VSM
|
https://kanbanize.com/lean-management/value-waste/value-stream-mapping Source-
Internet |
· Identification of waste areas and kaizen areas in trios
using matrix |
Construct future VSM |
|
22
|
Construction of Future VSM
|
https://kanbanize.com/lean-management/value-waste/value-stream-mapping Source- Internet |
· Construction VSM by students in trios |
Discussion Forum |
|
23
|
Implementation plan and Calculation of operators
required
|
https://kanbanize.com/lean-management/value-waste/value-stream-mapping Source- Internet |
·
Lecture on
implementation plan using PPT ·
Analysis of
number of operators required |
Self study: Calculate operators required for at least two VSM examples |
|
24
|
Jidoka- Development of Jidoka, why Jidoka and its
implementation
|
TB 1 page numbers 73-83 |
·
Spot activity on
Quality ·
Lecture on Jidoka
and its implementation |
Discussion Forum |
|
25
|
Poka Yoke systems
|
TB 1 page numbers 143-152 Video: https://www.youtube.com/watch?v=RdhJ5RQA8cU Source- Internet |
·
Discussion on
error proofing in daily life ·
Lecture on Poka
yoke systems |
List the Poka Yoke devices that use
encountered in your life |
|
26
|
Use of Poka Yoke in practice
|
TB 4 page numbers 241-268 |
·
Lecture on use of
poka yoke using PPT ·
Doubt
clarification |
Discussion Forum |
|
27
|
Inspection systems
|
TB 4 page numbers 241-268 |
·
Open Forum on
inspection systems ·
Lecture on
inspection systems using PPT |
Self Study- Advantages and Limitations of various inspection systems |
|
28
|
Inspection Systems and Zone of Control
|
TB 4 page numbers 241-268 |
·
Lecture on
inspection systems using PPT ·
Game on Zone of
control |
Discussion Forum on zone of control |
|
29
|
Unit-III –Kaizen
introduction, types, importance
|
· To make the students apply lean methodologies, tools and
techniques for building standardization.
|
TB 2 page numbers 153-160 Video: https://www.youtube.com/watch?v=-K-QIwXoGHE Source- Internet |
·
Self assessment on continuous
improvement
·
Lecture on Kaizen, types,
importance using PPT
|
List the kaizen movements that you observed in yourself |
30
|
Six Sigma Process – Philosophy
|
TB 3 page numbers 137-293 |
·
Discussion about
Dabbawala Video on Six Sigma ·
Lecture on Six
Sigma process, philosophy |
Study the six sigma practice of a select company |
|
31
|
Six Sigma Methodology
|
TB 2 page numbers 309-332 TB 3 page numbers 137-293 |
·
Lecture on six
sigma methodology ·
Doubt
clarification |
Discussion Forum |
|
32
|
Quality Function Deployment
|
TB 4 page numbers 302-346 |
·
Lecture on
Quality function deployment ·
Discussion on
Voice of customer |
Develop a sample QFD for a product or service |
|
33
|
Quality function Deployment
|
TB 4 page numbers 302-346 |
· Creation of Quality Function deployment with given data
and analysis |
Discussion Forum |
|
34
|
Failure Mode Effect Analysis (FMEA)
|
TB 4 page numbers 215-256 Video NPTEL: https://www.youtube.com/watch?v=7bFjH_ZVARI Source- Internet |
· Lecture on Failure Mode effect Analysis · Calculation of RPN |
Calculate the FMEA |
|
35-40
|
Student
Presentations
|
Mid 1 Assessment
|
Preparation of Mini report by
the Student on the given topic |
Minimum 10 Minutes Presentation
by each student |
Improvement
of presentation skills basing on faculty recommendations |
41
|
Statistical Process Control
|
|
TB 2 page numbers 417-472 TB 4 page numbers 175-211 |
· Lecture on Statistical process control · Preparation of control charts |
Self study: Uses, advantages and limitations of SPC |
42
|
Statistical Process Control
|
TB 2 page numbers 417-472 TB 4 page numbers 175-211 |
· Lecture on Statistical process control ·
Preparation of
Fishbone, sample check list, pareto diagram |
Practice statistical process control types- at least one case/ example for each type |
|
43
|
QC- standardized work in lean systems
|
TB 6 page numbers 153-181 |
·
Lecture on
standardization in Lean systems ·
Discussion on QC
role in standardization |
Discussion Forum |
|
44
|
Standards in Lean – 5S Systems
|
TB 4 page numbers 241-268 |
·
Lecture on 5S
systems ·
Short exercise on
implementing 5 s with given hints |
Write a note on 5s system used for self practice |
|
45
|
Unit-4 Total Productive Maintenance
(TPM) - Introduction
|
· To make
the student apply Total Productive Maintenance in improving effectiveness and
analyze common layouts of standardized work.
|
TB 4 page numbers 441-464 Video: https://www.youtube.com/watch?v=JgxN6DGbjUQ Source- Internet |
·
Lecture on Total
Productive Maintenance ·
Quiz on TPM |
Discussion Forum |
46
|
Calculation of OEE
|
TB 4 page numbers 441-464 |
·
Creation of TPM
form using given data ·
Calculation of
OEE ·
Analysis of TPM |
Calculate total productive maintenance- using cases |
|
47
|
Why Standardized work
|
TB 6 page numbers 153-181 |
· Lecture on Standardization of work using PPT · Discussion on standardization |
Write
real life example of standardized work |
|
48
|
Elements of Standardized work
|
TB 6 page numbers 153-181 |
· Elements of standardization · Calculation of Takt Time, WIP |
Calculate Takt type of 3 examples |
|
49
|
Charts to define standardized work |
Source- Internet |
· Lecture on charts define standardized work · Doubts clarification |
Discussion Forum |
|
50
|
Charts to define standardized work |
Source- Internet |
· Analysis on work charts of standardization |
Draw standardization work charts for practice- study the use of each chart and its objectives |
|
51
|
Kaizen and standardized work common layouts |
Source- Internet |
· Lecture on kaizen and standardized work layouts |
Discussion Forum – kaizen and common layouts |
|
52
|
Kaizen and standardized work common layouts |
Source- Internet |
·
Preparation of
standardized work layout for creating kaizen |
Self Analysis- Elicit the sources of kaizen through Standardization layouts |
|
53
|
Unit-5: Hoshin Planning introduction
|
· To make the student understand
lean culture, role of Quality circles and analyze the policy deployment of an
organization.
|
TB 4 page numbers 423-438 Video: https://www.youtube.com/watch?v=sY7CB3BnJmY Source- Internet |
·
Team activity on
strategy preparation and implementation ·
Lecture on
introduction to policy deployment |
Discussion Forum |
54
|
Creation of X Matrix
|
TB 4 page numbers 423-438 |
·
Discussion on
creation of X matrix ·
Preparation of X
matrix in teams |
Create a X matrix for a select strategy |
|
55
|
Four Phases of Hoshin Planning
|
TB 4 page numbers 423-438 |
·
Lecture on phases
of Hoshin Kanri using PPT ·
Assessment of
strategy deployment using Hoshin Kanri |
Discussion Forum |
|
56
|
Employee Involvement-activities supporting
involvement
|
TB 1 page numbers 47-58, 173-184 TB 2 page numbers 79-105 |
· Lecture on
Employee involvement in lean production · Doubts
clarification |
Team work – involvement of employees in TPS |
|
57
|
Quality circle activities
|
TB 2 page numbers 79-105 |
· Team exercise on
Quality circle formulation and conduct of meeting · Lecture on QC
activities using PPT |
Self study - QC of a select company |
|
58
|
Kaizen Training- Factors influencing PKT |
TB 4 page numbers 466-477 |
·
Discussion on
kaizen training ·
Lecture on PKT in
lean production using PPT |
Discussion Forum |
|
59
|
Lean Culture- How Lean Culture feels |
TB 1 page numbers 185-193 |
·
Lecture on Lean
culture and its impact on organization ·
Doubts
clarification |
PKT of a select company |
|
60-70
|
Student
Presentations
|
Mid 2 Assessment
|
Preparation of Mini report by
the Student on the given topic |
Minimum 10 Minutes Presentation
by each student |
Improvement
of presentation skills basing on faculty recommendations |
Evaluation:
·
Mini Report: 5 Marks for Mid 1 & Mid 2 Separately
(Write your assignments, case analysis and mini project on A4 papers and submit
the report)
·
Presentation: 5
·
Marks for Mid 1 & Mid 2 Separately (You
should present case analysis and mini
projects done during the mid)
·
Descriptive Exam: 15 Marks for Mid 1 &
Mid 2 Separately
·
Total Mid marks 25 Marks: Average of Mid 1
& Mid 2