Lean Manufacturing
Principles of lean manufacturing are
introduced that provide a systematic process for identifying and
eliminating non-value activities (waste) in production processes.
Students learn these principles through a series of mini-projects in the
mechanical engineering shop, an all-day factory simulation workshop, and
tours to local industry.
Course Materials and Resources
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Short Courses
- History of NUMMI, a joint GM and Toyota car plant.
Listen
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Week 1 - Introduction to Lean
Thinking and ME Shop
Day |
Lecture |
Laboratory |
Homework |
5/16 |
- Course Goals and
Syllabus
- Role of Engineering
Logbooks
- Mass Production vs.
Lean Enterprise System
- Lean Manufacturing Overview
- Plant Layout Models
- All I Need to Know
about Manufacturing I Learned in Joe's Garage
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Shop Introduction:
Logbooks:
Block Project:
Machine Plan Template:
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1. Include at least one photo and annotation in your
logbook each day that describes something interesting you did or
learned in the shop.
2. Read Joe's Garage and select four terms from
the
lean building blocks diagram that are well-illustrated in
Joe's Garage. Define and explain each of these terms using
examples from Joe's Garage.
3. In preparation for the block project: a) review the part
drawings,
b) find information on the following items in the Machine Shop
portion of the Mindworks website, and
c) outline a process how you might fabricate each part.
- lathe parts/operation
- mill parts/operation
- edge finder
- endmills
- taps/dies
- boring bar
- chamfer/deburring tools
- fits/tolerances
- machining plans
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5/17 |
- Discussion of Joe’s Garage
- House of Lean Terms
- Types of Waste
- Introduction to 5S
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Shop team formation
Group A: Mill Project
Group B: Lathe Project
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1. Identify four concepts from the glossary of Joe’s
Garage that are illustrated in the shop or design suite.
Explain each concept and give a detailed description how each
concept is implemented.
2. Create manufacturing plan for mill and lathe portions of
block project (to be updated during the project).
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5/18 |
- Lean Methodology
- Lean Building Blocks
- Kaizen Methodology
- The 5 Whys
- Fishbone Diagrams
- Spaghettis Diagrams
- 5S Audit Scorecard
- Kaizen Projects
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Group A: Mill
Project
Group B: Lathe Project
Kaizen Projects:
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1. Prepare for Kaizen Project Work:
a) review ASEE Presentation (PDF,
PPT) on just in time resources for project learning,
b) review
ASEE paper on QR code development for ME shop, and
c) examine just-in-time shop learning resources on the
Machine Shop webpage as well as the
Mindworks Shoutwiki site.
2. Compose a logbook analysis that:
a) defines the current state surrounding
your kaizen project, and
b) defines a credible and value-added future
state/goal that can be achieved by your Kaizen team by course
end.
3. Identify resources and begin project learning for Kaizen
projects.
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5/19 |
- Value Stream Mapping
- Present State Map
- Process Improvement Strategies
- Takt Time
- Future State Map
- Preparation for Factory Simulation Workshop
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Group A: Mill Project
Group B: Lathe Project |
1. Generate manufacturing plan for 2nd half of the Block
Project.
2. Create and analyze Present State map for the boat
factory. Include as much process information as possible. Identify
at least two lean concepts that could be implemented in a future
state.
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5/20 |
- No Lecture
- NOTE EXTENDED LABS:
AM LAB 8:30-noon
PM LAB 1:00-4:30
Meet in GJ112
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Factory Simulation
Workshop:
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1. Construct a Future State Map based on the final
iteration of the boat factory simulation.
2. Discuss discoveries/lessons learned from lean workshop.
3. Analyze statistics from the boat factory simulation:
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Week 2
- Apply Lean Concepts in Shop, CAD Lab, and Kaizen Projects
Day |
Lecture |
Laboratory |
Homework |
5/23 |
- Workshop Debrief
- Planning for logbook and Kaizen project review
- All that Matters About Quality I Learned in
Joe's Garage
- Work Cell Design and Setup Reduction
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Exchange block parts(with
complementary team, i.e. mill team exchanges with lathe team) and
analyze tolerances.
Group A: Lathe Project
Group B: Mill Project
Kaizen Projects:
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1. Kaizen Project Work
2. Complete a
Logbook Review Form (all portions) and tape it into your
logbook. Bring your logbook to class.
3. Bring to class copies of key elements of your kaizen
project work to date (logbook notes, reference material, and a
completed
Feedback Form) for
display during the kaizen mid-project peer review.
4. Document and
discuss findings from block exchange. Consider the following
in your discussion:
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5/24 |
-
Logbook review activity
- Kaizen mid-project review
- Planning for tours
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Group A: Lathe Project
Group B: Mill Project
Kaizen Project Prep |
1. Kaizen Project Work
2. Block Project write-up due by 5 pm on Wednesday 5/25.
3. Read pages 1-64 from All That Matters About Quality...
In your logbook, answer the first batch of
reflection questions by Friday.
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5/25 |
- Discussion of All That Matters About Quality
(batch 1)
- Planning for tours
Day 11 Slides: Value
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Group A: Lathe Project
Kaizen Project Prep
Group B: Mill Project
Kaizen Project Prep
Block Project Write-up
due by 5 pm (place on
a wooden table in
design suite along with
your hardware) |
1. Kaizen Project Work
2. Read pages 65-130 from All That Matters About
Quality.... In your logbook, answer the second batch of
reflection questions.
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5/26 |
Plant Tours:
closed
toed/heeled shoes
no
sandals/heels/boots
long
hair tied back
long
pants, no shorts
safety
equip. provided
no
pictures at SEL
electronics off at SEL
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Tour
Schedule:
gather
time: 8:15
location:
red lot 64B
depart time: 8:30 am
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1. Kaizen Project Work
2. Note context and discuss of scavenger hunt items.
3. Formulate any outstanding questions that you would like
to explore in tomorrow's debrief of the plant tours.
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5/27 |
- Plant Tour Debrief
-
Discussion of All That Matters About Quality (batch
2)
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Final Project Descriptions
Final Project Score sheet |
1. Kaizen Project Work
2. Final Project Work
Videos:
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Week 3 - Mini-Projects and End of
Course Deliverables
Day |
Lecture |
Lab |
HW |
5/30 |
MEMORIAL DAY - NO CLASS
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5/31 |
- Review for exam
- Takt Time
- Internal/External Setup
- Line Balancing
- Poka-Yoke
- Chaku Chaku
- Heijunka Boards
Exam Prep Resources:
- Lecture Slides
- Lecture Notes
- Distributed Texts
- Plant Tour Notes
- Factory Simulation Notes
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Kaizen Project Work
Final Project Work
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1. Use your logbook to synthesize your understanding of lean
manufacturing concepts in preparation for the in-class exam:
- House of Lean
- Types of Waste
- Plant Layouts
- 5S Systems
- Visual Controls
- Kaizen Events
- Value Stream Maps
- Just-in-Time
- Quality at the Source
- Work Cell Design
- Set-Up Reduction
- Product Families
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6/1 |
- In-Class Exam
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Inventory remaining action items and implementation plans
associated with Kaizen project and Final project
Kaizen Project Work
Final Project Work
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1. Kaizen Project Work
2. Final Project Work
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6/2 |
- Exam Recap
- Course Deliverables
-
Course Assessment
- Snapshot Preparation:
- Kaizen Project Display
- Final Project Display
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Kaizen Project Work
Final Project Work
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1. Record insights from exam recap.
2. Complete a summative
Logbook Review Form looking back across the entire course.
3. Kaizen Display (use foam core to pin up printouts
and/or display hardware on tables)
- Current state
description and analysis
- Desired future state/goal
- Physical or electronic
product for others to explore (as
appropriate)
- NOTE: Review your display with a mentor,
an instructor, and Russ before class
4. Final Project Display
(PM teams to show work-in-progress
if not complete)
- Dimensioned Drawings
- CAD Visualization
- Manufacturing Plan
- Hardware Artifact
- Relevant Pictures
- Relevant Discussion
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6/3 |
- Block Project Display
- Kaizen Project Display
- Final Project Display
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Final Work in Shop
Shop and Design Suite Clean-Up
Compilation of Course Deliverables
Final Project Score Sheet
Logbook Review Form
Kaizen Proj. Score
Sheet
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Course Deliverables by 5:00 pm
1. Kaizen Project:
- Leave display out after Snapshot Event
- Wiki pages must be approved by the Wiki mentors;
address issues on your discussion page
- Artifacts and drawing packages should be logged
with Russ Porter
- Files should be logged with Steve Beyerlein
2. Final Project
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Leave out after Snapshot event
3. Personal Logbook
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Place in milk crate within design suite
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