The main aim of this module is to develop a learner’s ability to successfully combine and apply a variety of Lean tools and techniques to manufacturing system problems while developing in learners an awareness of the cultural and management challenges associated with Lean implementation. The module also introduces learners to continuous improvement approaches including the Six Sigma DMAIC approach and to the application of Lean in the design phase. It requires learners to individually research Lean Operations questions and challenges learners to integrate the skills and knowledge learned in this module and to apply them critically to more complex projects.
1.0 Traditional Manufacturing Systems (the organisation of classical push manufacturing)
2.0 Lean Principles (Process Focus, Elimination of Barriers to flow, 7 Wastes (Muda), Fluctuation (Mura), and Overburden (Muri), Visual Management, Stability, Standardisation, Jidoka, Lot Size Reduction)
3.0 Application of Lean Tools & Techniques (Value Stream mapping, TPM, SMED, 5S, ZQC & PokaYoke)
4.0 Lean Metrics (TAKT time, OEE, % Value Add etc.)
5.0 Designing for Flow in Manufacturing (Kanban & Heijunka Boxes)
6.0 Lean & Sustainability Principles applied in Product Design Phase
7.0 Incremental Continuous Improvement (Kaizen). Six Sigma DMAIC approach
8.0 Lean Leadership/Cultural Enabler Techniques & Practices of Lean
