| Title: | Lean Manufacturing |
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| Long Title: | Lean Manufacturing |
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| Field of Study: |
Chemical & Process Eng
|
| Valid From: |
Semester 2 - 2016/17 ( January 2017 ) |
| Module Coordinator: |
David Goulding |
| Module Author: |
CILIAN O SUILLEABHAIN |
| Module Description: |
This module provides an introduction to methods, concepts, and theories associated with lean
manufacturing, including topics such as Total Quality Management (TQM) and Six Sigma.
Techniques such as Just in Time and Kanban, are explained. Decision making and problem
solving tools such as control charts, process flow diagrams, Pareto charts, and fishbone charts
are explained. |
| Learning Outcomes |
| On successful completion of this module the learner will be able to: |
| LO1 |
Explain the approaches to, concepts, and theories of Lean Manufacturing, including key aspects of Just
in Time and Six Sigma. |
| LO2 |
Apply World Class Manufacturing (WCM) techniques to effect continuous improvement. |
| LO3 |
Apply Analytical Troubleshooting (ATS) techniques to technical problem solving and decision making. |
| LO4 |
Explain people management issues and discuss how they can be addressed. |
| Pre-requisite learning |
Module Recommendations
This is prior learning (or a practical skill) that is strongly recommended before enrolment in this module. You may enrol in this module if you have not acquired the recommended learning but you will have considerable difficulty in passing (i.e. achieving the learning outcomes of) the module. While the prior learning is expressed as named MTU module(s) it also allows for learning (in another module or modules) which is equivalent to the learning specified in the named module(s).
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Incompatible Modules
These are modules which have learning outcomes that are too similar to the learning outcomes of this module. You may not earn additional credit for the same learning and therefore you may not enrol in this module if you have successfully completed any modules in the incompatible list. |
| 9715 |
CHEP8019 |
Process Quality Management |
Co-requisite Modules
|
| No Co-requisite modules listed |
Requirements
This is prior learning (or a practical skill) that is mandatory before enrolment in this module is allowed. You may not enrol on this module if you have not acquired the learning specified in this section.
|
| No requirements listed |
Module Content & Assessment
| Indicative Content |
|
Lean Manufacturing
Principles and application of Lean Manufacturing. Waste processes versus value added processes.
Continuous improvement. Employee involvement. Process Analytical Technology (PAT).
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Just in Time
Just in Time, scope, challenges, benefits, effect on quality, finance, and efficiency, process layouts.
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Six Sigma
Principles, tools comparison of Six Sigma with Lean.
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Decision Making & Technical Problem Solving
Analytical trouble-shooting techniques, SQC tools, Pareto and fishbone charts, Kepner Tregoe, SIPOC, DMAIC, Why-Why analysis, benchmarking, improvement priorities - important to customers, polar diagrams, continuous and breakthrough improvement.
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Process Mapping
Following process flows and mapping processes on flowcharts. Process bottlenecks and the most effective methods to de-bottleneck. Cycle-time analysis.
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People Involvement
Employee empowerment and development. Education training and development. Long term commitment. Unity of purpose. Teamwork. Accelerated change management. Influencing the organisation mindset and culture to deal with and adapt to change.
|
| Assessment Breakdown | % |
|---|
| Course Work | 30.00% |
| End of Module Formal Examination | 70.00% |
| Course Work |
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| Assessment Type |
Assessment Description |
Outcome addressed |
% of total |
Assessment Date |
| Short Answer Questions |
Lean Manufacturing, WCM and ATS Techniques |
1,2,3 |
10.0 |
Week 6 |
| Written Report |
Book review assignment |
1,2 |
20.0 |
Week 8 |
| End of Module Formal Examination |
|---|
| Assessment Type |
Assessment Description |
Outcome addressed |
% of total |
Assessment Date |
| Formal Exam |
End-of-Semester Final Examination |
1,2,3,4 |
70.0 |
End-of-Semester |
| Reassessment Requirement |
Repeat examination
Reassessment of this module will consist of a repeat examination. It is possible that there will also be a requirement to be reassessed in a coursework element.
|
The institute reserves the right to alter the nature and timings of assessment
Module Workload
| Workload: Full Time |
| Workload Type |
Workload Description |
Hours |
Frequency |
Average Weekly Learner Workload |
| Lecture |
No Description |
3.0 |
Every Week |
3.00 |
| Independent & Directed Learning (Non-contact) |
Assignment and student study |
4.0 |
Every Week |
4.00 |
| Total Hours |
7.00 |
| Total Weekly Learner Workload |
7.00 |
| Total Weekly Contact Hours |
3.00 |
| Workload: Part Time |
| Workload Type |
Workload Description |
Hours |
Frequency |
Average Weekly Learner Workload |
| Lecture |
No Description |
3.0 |
Every Week |
3.00 |
| Independent & Directed Learning (Non-contact) |
Assignment and student study |
4.0 |
Every Week |
4.00 |
| Total Hours |
7.00 |
| Total Weekly Learner Workload |
7.00 |
| Total Weekly Contact Hours |
3.00 |
Module Resources
| Recommended Book Resources |
|---|
- Pound, E.S., Bell, J.H. and Spearman, M.L. 2014, Factory Physics for Managers: How Leaders Improve Performance in a Post-Lean Six Sigma World, 1st Ed., McGraw Hill Professional New York [ISBN: 007182250X]
- Mary Walton 1991, Deming management at work, Perigee Books New York, NY [ISBN: 0399516859]
| | Supplementary Book Resources |
|---|
- Thomas Pyzdek 2003, The Six Sigma handbook, McGraw-Hill New York [ISBN: 0071410155]
- Nigel Slack, Stuart Chambers, Robert Johnston 2007, Operations management, Prentice Hall/Financial Times Harlow, England [ISBN: 0273708473]
- W. Edwards Deming 1986, Out of the Crisis, 1 Ed., 17, Cambridge University Press Cambridge [ISBN: 0521305535]
- Daniel Roos, 2007, The Machine That Changed the World, 1 Ed., 10, Simon and Schuster London [ISBN: 1847370551]
- Kenneth Blanchard, Spencer Johnson 1983, The one minute manager, Fontana London [ISBN: 00063 67534]
- Philip Crosby, Quality is Free [ISBN: 978-0451622471]
- Peter F. Drucker 2006, The Effective Executive, 1 Ed., 8, Collins New York [ISBN: 978-0060833459]
- Jeffrey K. Liker 2004, The Toyota Way, McGraw-Hill New York [ISBN: 0071392319]
- Dennis P. Hobbs 2004, Lean Manufacturing Implementation, 1 Ed., 9, J Ross Publishing Boca Raton, Florida, USA [ISBN: 1932159142]
- Brian K. Nunnally, John S. McConnell, Six Sigma in the Pharmaceutical Industry [ISBN: 1420054392]
- edited by Nikkan Kogyo Shimbun, Ltd./factory magazine; with a preface by Shigeo Shingo; publisher's foreword by Norman Bodek 1988, Poka-yoke, Productivity Press Cambridge, Mass. [ISBN: 0915299313]
- J. M. Juran, Frank M. Gryna 1993, Quality Planning and Analysis, McGraw-Hill New York [ISBN: 0070331839]
- Greg Brue and Rod Howes 2006, Six Sigma, McGraw-Hill New York [ISBN: 0071430083]
| | This module does not have any article/paper resources |
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| This module does not have any other resources |
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Module Delivered in
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