Learning outcomes of the course unit
Knowledge and ability to understandAt the end of the course, the students will acquire the basic knowledge related to the lean manufacturing philosophy.SkillsStudents will be able to design a manufacturing system according to lean principles, defining the most suitable management policies about the application of manufacturing planning system, kitting strategies and assembly lines feeding.Autonomy of judgementThe student should be able to critically evaluate a production system; or design, choose and implement the basic lean manufacturing tools.Communication skillsStudents will acquire the specific vocabulary relating to lean manufacturing and Just In Time theory. It is expected that, by the end of this course, the student can communicate, orally and in writing, also by means of solutions of numerical problems, the main content of the course.Learning abilityStudents who have attended the course will be able to deepen their knowledge in the field of production management, through the autonomous consultation of specialized texts, scientific or for practitioner’s journals or, even outside of the topics covered tightly to class.
No mandatory prerequisite.Desirable the frequency and the overcoming of class related to the design of production systems, manufacturing planning and control system and statistics.
Course contents summary
Improving efficiency and achieving operational excellence involve the study and the implementation of continuous improvement approach.The aim of this course is to present, in a concrete way, methods, tools and models to design and manage a production system according to pull production philosophies able to reach operational excellence.
PUSH-PULL PRODUCTION SYSTEMSINTRODUCTION TO LEAN MANUFACTURINGWASTE / MUDA IDENTIFICATIONVALUE STREAM MAPPINGSEIRI, SEITON, SEISO, SEIKETSU, AND SHITSUKE: 5 S METHODOLOGYSINGLE MINUTE EXCHANGE OF DIE (SMED)CREATING CONTINUOUS FLOWMAKING MATERIALS FLOWJUST IN TIME (JIT)THE SYNCHRO-MRP SYSTEMTHE CONWIP SYSTEMTHE WORKLOADS WIP CONTROLTHE OPTIMISE PRODUCTION TECHNOLOGY (OPT)THE POLCA (PAIRED-CELL OVERLAPPING LOOPS OF CARDS WITH AUTHORIZATION)
TESTI IN INGLESEHIROYUKI HIRANO, (2009), “JIT Implementation Manual. The Complete Guide to Just-in-Time Manufacturing”Vol.1 - The Just-In-Time Production System; Vol.2 - Waste and 5S; Vol.3 - Flow Manufacturing - Multi-Process Operations & Kanban; Vol.4 - Leveling - Changeover & Quality Assurance; Vol.5 - Standardized Operations - Jidoka & Maintenance-Safety; Vol.6 - JIT Implementation Forms & Charts, CRC Press
Theory lessons interspersed with exercises and case studies.
Assessment methods and criteria
The exam consists of the discussion of a project developed by a group of students