Learning outcomes of the course unit
KNOWLEDGE AND ABILITY TO UNDERSTAND
At the end of the course, the students will acquire the basic knowledge related to the lean manufacturing philosophy.
ABILITY TO APPLY KNOWLEDGE AND UNDERSTANDING
Students 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.
The student should be able to critically evaluate a production system; or design, choose and implement the basic lean manufacturing tools.
Students 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.
Students 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.
1. PUSH-PULL PRODUCTION SYSTEMS
2. INTRODUCTION TO LEAN MANUFACTURING
3. WASTE / MUDA IDENTIFICATION
4. VALUE STREAM MAPPING
5. SEIRI, SEITON, SEISO, SEIKETSU, AND SHITSUKE: 5 S METHODOLOGY
6. SINGLE MINUTE EXCHANGE OF DIE (SMED)
7. CREATING CONTINUOUS FLOW
8. MAKING MATERIALS FLOW
9. JUST IN TIME (JIT)
10. THE SYNCHRO-MRP SYSTEM
11. THE CONWIP SYSTEM
THE WORKLOADS WIP CONTROL SYSTEM
1. ROYUKI 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