Learning objectives
Knowledge and understanding
At the end of the course, the student will be able to analyse a production system and design a lean manufacturing solution for its management and its control.
Applying knowledge and understanding
The student will be able to design a production system and methods of planning and control of production according to the paradigms of lean production. By way of example, but not limited to, the student will be able to design the manufacturing / assembly cells, to create the continuous flow for manufacturing / assembly cell, to choose between a push, pull or hybrid control systems and so on.
Making judgements
The student will be able to assess the impact of production planning choice on manufacturing performances of the production system.
Communication skills
The student must acquire the basic vocabulary inherent the principles of lean manufacturing and JIT. It is expected that at the end of the course, the student is able to communicate, orally and writing, including the resolution of numerical problems, the main contents of the course (eg: push and pull systems, identification of losses, value stream mapping, etc..).
Learning skills
Students who have attended the course will be able to deepen their knowledge in the field of pull production in general, by consulting their own texts specialized journals or dissemination, even outside of the topics covered closely in class.
Prerequisites
There are no compulsory prerequisites, but students are advised to have attended the course of Industrial Logistics and Operations Management.
Course unit content
In an increasingly competitive business environment, in which the reduction of lead times, product lot size and product costs is a critical factor of success, we need to rethink both the design and the management of production systems. The course aims to introduce the main tools for the design and management of production systems using the principles of lean manufacturing.
Full programme
Push-pull systems
Introduction to Lean
Waste identification
The JIT (Just In Time) system and kanban production control
The CONWIP (Constant Work In Process) system
The integration of JIT and MRP: the Synchro-MRP system
Workload Control
The Optimise Production Technology (OPT) system
The POLCA (Paired-cell Overlapping Loops of Cards with Authorization) system
Value Stream Mapping
IDEF 0
Cross-functional diagram
BPMN
Single Minute Exchange of Die (SMED)
The 5S methodology: i) Seiri (sorting-separated); ii) Seiton (stabilizing or straighteining-order); iii) Seiso (sweeping or shining - clean); iv) Seiketsu (standardizing - systematize or standardize); v) Shitsuke (susteining the practice - to spread or support)
Creating Continuous Flow
Making Material Flow
Lean Accounting
Perfomance measurement
Lean financial accounting
Value stream costing
Target costing
Throughput Accounting and Just In Time Accounting
Lean Organization
Case studies
Bibliography
Hiroyuki Hirano, (2009), JIT Implementation Manual Vol.1 - The Just-In-Time Production System. Taylor & Francis Group
Hiroyuki Hirano, (2009), JIT Implementation Manual Vol.2 - Waste and 5S. Taylor & Francis Group
Hiroyuki Hirano, (2009), JIT Implementation Manual Vol.3 - Flow Manufacturing - Multi-Process Operations & Kanban. Taylor & Francis Group
Hiroyuki Hirano, (2009), JIT Implementation Manual Vol.4 - Leveling - Changeover & Quality Assurance. Taylor & Francis Group
Hiroyuki Hirano, (2009), JIT Implementation Manual Vol.5 - Standardized Operations - Jidoka & Maintenance-Safety. Taylor & Francis Group
Hiroyuki Hirano, (2009), JIT Implementation Manual Vol.6 - JIT Implementation Forms & Charts. Taylor & Francis Group
Teaching methods
The theoretical topics of the course are explained by means of lectures. Exercises and business cases are proposed on the practical parts of the course. Moreover, business cases are discussed as examples of the main theoretical arguments of the course. Finally, seminars with the intervention of companies representatives are organized during the course.
Assessment methods and criteria
The exam consists of a oral discussion of a project.
Other information
Pdf files of class activities are made available upon request through a shared internet platform.
