Course

Unit 1

Introduction to Lean and Factory Simulation: History of Lean and comparison to other methods – The 7 Wastes, their causes and the effects – An overview of Lean Principles / concepts / tools – Stockless Production.

The Tools of Lean Manufacturing: Continuous Flow – Continuous Flow Manufacturing and Standard Work Flow – 5S and Pull Systems (Kanban and ConWIP systems) – Error Proofing and Set-up Reduction – Total Productive Maintenance (TPM) – Kaizen Event examples. Toyota production systems.

Ford production systems – FPS gear model

Unit 2

Value Stream Mapping – Current state: Preparation for building a Current State Value Stream Map – Building a Current State Map (principles, concepts, loops, and methodology) – Application to the factory Simulation scenario.

Unit 3

Value Stream Mapping – Future State: Key issues in building the Future State Map – Process tips in building the map and analysis of the customer loop, supplier loop, manufacturing loop and information loop – Example of completed Future State Maps – Application to factory simulation

Implementation of lean practices – Best Practices in Lean Manufacturing.

Course Objectives

• Understand Lean manufacturing principles and tools
• Inculcate the concepts of value stream mapping
• Familiarize lean implementation practices

Course Outcomes 

CO1: Identify key requirements and concepts in lean manufacturing.

CO2: Initiate a continuous improvement change program in a manufacturing organization CO3: Analyze and improve a manufacturing system by applying lean manufacturing tools CO4: Build value stream map for improving the productivity

CO5: Improve productivity through lean practices

CO/PO Mapping 

Evaluation Pattern 

*CA – Can be Quizzes, Assignments, Projects, and Reports 

TEXT BOOKS

1. Womack, P., Jones, D.T., and Roos, D.,‘The Machine that Changed the World’, Simon & Schuster, New York, 2007.
2. Liker, K., ‘Becoming Lean’, Industrial Engineering and Management Press, 1997.

REFERENCES BOOKS

1. Womack, P. and Jones, D.T.,‘Lean thinking’, Simon & Schuster, USA, 2003.
2. Rother, and Shook, J., ‘Learning to see’, The Lean Enterprise Institute, Brookline, USA, 2003.