Module 1

Module 1: Flexible Manufacturing Systems (FMS) (10 hours)

1. FMS Introduction, Manufacturing Cell, Group Technology, Machining Centers.
2. Automated Material Movement and Storage System.

Module 2

Module 2: Lean Manufacturing Systems (10 hours)

1. Lean Manufacturing through Waste Elimination.
2. Value Stream Mapping, Kaizen in Lean Manufacturing Paradigm, Pull Production through Kanban Card System.
3. One Piece Flow Production System, Visual Management, Lean Manufacturing through Total Productive Maintenance.
4. Implementation of Lean Manufacturing Paradigm in Traditional and Moderate Organizations.

Module 3

Module 3: Agile Manufacturing Systems (10 hours)

1. The Fundamental Structure of Agile Manufacturing Paradigm.
2. Agile Manufacturing through Management Driver.
3. Agility through Technology Driver.
4. Agility through Manufacturing Strategy Driver.
5. Agility through Competitive Driver,
6. Implementation of Agile Manufacturing Paradigm in Moderate and Smart Organizations.

Course Description

Modern industry requires managers who can effectively deploy modern approaches to manufacturing. In recent times, flexible, lean and agile manufacturing has become a major area of attention to managers owing to its strong impact on profitability and efficiency. Manufacturing firms are increasingly adopting lean and agile systems to gain competitive advantage. Lean systemscould eliminate wastes and streamline the manufacturing process. Agile systems enable the speedy production and deliver variety of products in a cost effective manner. Although many manufacturing organizations around the world have adopted a combination of lean and agile systems in practice, cohesive procedures are yet to evolve for successful implementation. In this context, this course is designed for imparting knowledge on modern manufacturing systems which are largely dominated by flexible, lean and agile manufacturing principles.

Manufacturing Systems course is organized in three modules. It opens with the basic concepts of Flexible Manufacturing System (FMS), and then focuses on lean manufacturing principles with their application procedures in both traditional and modern organizations. It then focuses on the agile manufacturing principles and its implementation under four drivers: management, technology, manufacturing strategy and competitiveness. This course uses case studies related to application of flexible lean and agile manufacturing for effective learning to manage modern manufacturing systems and face challenges in competitive markets.

Course Outcomes& Learning levels

The course aims to impart learning that is required for a student to be a competent business professional and contribute value in a manufacturing organization in his/her early career. It is divided into three modules with distinct learning outcomes for each. On completion of this course, students will be,

1. Able to identify the differences between past and present methods of managing manufacturing systems and importance of flexible manufacturing systems. (Analyze).
2. Able to apply lean tools and techniques, in waste elimination in manufacturing systems (Create).
3. Able to analyze the agile manufacturing systems, applications in moderate and smart manufacturing firms. (Evaluate).

Evaluation Pattern

* Based on assignments / Tests / Quizzes / Case Studies / Projects / Term paper / Field visit report.

Course Text

1. Devadasan, S. R., Sivakumar, V. M., Murugesh, R., Shalij, P. R.,”Lean and Agile Manufacturing: Theoretical, Practical and Research Futurities,” 2012, Prentice-Hall of India Pvt. Ltd. India.

Reference Books

1. Kaighobadi, M., & Venkatesh, K. (1994). Flexible manufacturing systems: an overview. International Journal of Operations & Production Management, 14(4), 26-49.
2. Mishra, R., K. Pundir, A., & Ganapathy, L. (2014). Assessment of manufacturing flexibility: A review of research and conceptual framework. Management research review, 37(8), 750-776.