ANDHRA LOYOLA
INSTITUTE OF ENGINEERING AND TECHNOLOGY
Department:
MBA Subject: LEAN
MANAGEMENT Year/Semester: I Year /II Semester
Teacher : LAVANYA P B Academic Year: 2020-21
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
Contents/Activities:
1
|
Factual: |
·
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: |
·
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: |
·
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: |
·
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 |
Discussion Forum |
|
3
|
Mass Production |
TB 5 page numbers |
· Lecture on Mass production
characteristics using PPT · Discussion on
advantages and disadvantages of Mass Production |
Discussion Forum |
|
4
|
Craft Production
|
TB 5 page numbers |
· Lecture on Craft
production characteristics using PPT · Discussion on
advantages and disadvantages of craft Production |
Discussion Forum |
|
5
|
Lean Production Introduction
|
TB 1 page numbers 1-24 |
· Lecture on Lean
production characteristics using PPT · Video of TPS |
Discussion Forum |
|
6
|
Evolution of Lean Production |
TB 1 page numbers 1-24 |
· 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 |
· Lecture on Toyota
House pillars using PPT · Paired work on
identifying companies using Lean production |
Discussion Forum |
|
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 |
Discussion Forum |
|
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 |
|
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 |
Discussion Forum |
|
12
|
Waste Management
|
TB 1 page numbers 59-71 |
· Lecture on Waste
Management using PPT · Doubt clarification
|
Discussion Forum |
|
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 |
· Discussion on case
of Amul Milk Production · Lecture on introduction
to JIT using PPT |
Discussion Forum |
14
|
Kanban- Types of Kanban, Rules
|
https://kanbanize.com/kanban-resources/getting-started/what-is-kanban |
· 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 |
· 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/ |
· Lecture on Heijunka
using PPT · Exercise on
calculating production leveling |
Discussion Forum |
|
17
|
Three Types of Pull System |
· Lecture on Three
Types of pull systems using PPT · Doubt clarification |
Discussion Forum |
||
18
|
Three Types of Pull Systems |
· Lecture on Three
Types of pull systems using PPT ·
Comparison of Three types of pull in Trios |
Discussion Forum |
||
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 |
· Introduction to VSM using PPT · Discussion on various metrics used in VSM |
Discussion Forum |
|
20
|
Construction of Current VSM |
https://kanbanize.com/lean-management/value-waste/value-stream-mapping |
·
Construction of VSM by students
using hints in trios |
Discussion Forum |
|
21
|
Calculation of metrics for VSM
|
https://kanbanize.com/lean-management/value-waste/value-stream-mapping |
· Identification of waste areas and kaizen areas in trios using matrix |
Discussion Forum |
|
22
|
Construction of Future VSM
|
https://kanbanize.com/lean-management/value-waste/value-stream-mapping |
· 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 |
·
Lecture on implementation plan using
PPT ·
Analysis of number of operators
required |
Discussion Forum |
|
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 |
·
Discussion on error proofing in
daily life ·
Lecture on Poka yoke systems |
Discussion Forum |
|
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 |
Discussion Forum |
|
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 |
|
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 |
· Self
assessment on continuous improvement
· Lecture
on Kaizen, types, importance using PPT
|
Discussion Forum |
30
|
Six Sigma Process – Philosophy
|
TB 3 page numbers 137-293 |
·
Discussion about Dabbawala Video on
Six Sigma ·
Lecture on Six Sigma process,
philosophy |
Discussion Forum |
|
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 |
Discussion Forum |
|
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 |
· Lecture on Failure Mode effect Analysis · Calculation of RPN |
Discussion Forum |
|
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 |
Discussion Forum |
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 |
Discussion Forum |
|
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 |
Discussion Forum |
|
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 |
·
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 |
Discussion Forum |
|
47
|
Why Standardized work
|
TB 6
page numbers 153-181 |
· Lecture on Standardization of work using PPT · Discussion on standardization |
Discussion Forum |
|
48
|
Elements of Standardized work
|
TB 6
page numbers 153-181 |
· Elements of standardization · Calculation of Takt Time, WIP |
Discussion Forum |
|
49
|
Charts to define standardized work |
https://www.lean.org/common/display/?o=2187#:~:text=The%20standardized%20work%20chart%20shows,machine%20and%20overall%20process%20layout.&text=The%20standardized%20work%20chart%20is,table%20and%20job%20instruction%20sheet. |
· Lecture on charts define standardized work · Doubts clarification |
Discussion Forum |
|
50
|
Charts to define standardized work |
https://www.lean.org/common/display/?o=2187#:~:text=The%20standardized%20work%20chart%20shows,machine%20and%20overall%20process%20layout.&text=The%20standardized%20work%20chart%20is,table%20and%20job%20instruction%20sheet. |
· Analysis on work charts of standardization |
Discussion Forum |
|
51
|
Kaizen and standardized work common layouts |
https://www.lean.org/common/display/?o=2187#:~:text=The%20standardized%20work%20chart%20shows,machine%20and%20overall%20process%20layout.&text=The%20standardized%20work%20chart%20is,table%20and%20job%20instruction%20sheet. |
· Lecture on kaizen and standardized work layouts |
Discussion Forum |
|
52
|
Kaizen and standardized work common layouts |
https://www.lean.org/common/display/?o=2187#:~:text=The%20standardized%20work%20chart%20shows,machine%20and%20overall%20process%20layout.&text=The%20standardized%20work%20chart%20is,table%20and%20job%20instruction%20sheet. |
·
Preparation of standardized work
layout for creating kaizen |
Discussion Forum |
|
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 |
·
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 |
Discussion Forum |
|
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 |
Discussion Forum |
|
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 |
Discussion Forum |
|
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 |
Discussion Forum |
|
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
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