This module is a wide-ranging introductory module to Operations and Quality Management. It exposes students to the role, importance and key objectives of both the Operations and Quality Management functions. Building on theoretical foundation and “best practice approaches” approaches introduced, it is focused on developing Level 7 Engineering students’ knowledge, know-how, skill and competence in addressing a broad spectrum of Operations and Quality Management problems. Students are introduced to the fundamental approaches, and measurement and analytical tools/ techniques used in Operations and Quality Management problems. The module equips students with the capability to select, apply and interpret these techniques in support of Operations and Quality Management challenges. The “problem types” covered apply to a broad spectrum of Operations and Quality Management application areas. Industrial examples are used extensively.
Context of Operations Mgt: Role, dimensions, key objectives/responsibilities of Ops. Mgt.
Classification of Manufacturing Systems. Batch, Continuous and Discrete Manufacturing. Automated Single Station Manufacturing Cells, Transfer Lines, Automated Assembly Systems.
Manufacturing System Performance: Manipulating Operations Performance Analysis Metrics (including Efficiency and Productivity) for a variety of types of Manufacturing Systems
Capacity Planning and Control: Definition of Capacity, Capacity Measurement using OEE, Line Balancing
Enterprise Resource Planning: Introduction to Multi-level BOMS, MRP II and the MRP netting process and MRP calculations
ISA Standards: Introduction to ISA-95, Purpose, Terminology & Models For Integration Between the Control and Enterprise Layers. Introduction to ISA-88 Standard for Batch Process Control. Specific Emphasis On Parts 3 & 4 in both cases
Lean & Sustainable Manufacturing: Lean versus Trad. Manufacturing, 7 Wastes of Lean, Identification & Elimination of Barriers to flow, Lean Metrics, Fundamental Lean & Sustainable Tools and Techniques including Kanban and SMED, Triple Bottom Line, Life-Cycle Assessment, Design for Disassembly, Corporate Social Responsibility
Quality Systems Introduction and Fundamentals: The role, dimensions and impact of Quality in contemporary Industry, Basic elements of all Quality Control system, Elements of Quality Cost, Attributes/Variables, The role of Calibration
Managing Supply Chain Quality: Sampling Inspection, Auditing, Ethics and Vendor Relationships
Operations Quality Control: Standard Work, 5S for Operators, Visual Control, Quality Documentation, Role of Standards, ISO9000:2015 & ISO14001:2015 Sector-specific standards, Zero Quality Control, Poke-Yoka Failsafing Methods, Operations Quality Metrics (PPM, DPM), Introduction to Validation
Using Basic Quality Tools: Brainstorming, Pareto Analysis, Ishikawa Diagrams, CAPA Systems, Root Cause Analysis.
Process Capability/Process Control: Process capability (Cp, Cpk), Special Causes and Common Causes of Variation, Process control charts for variables: X-R charts.
