Course Outline UCLA Extension Department of Engineering, Information Systems & Technical Management

Transcription

1 Course Outline UCLA Extension Department of Engineering, Information Systems & Technical Management Course Number & Title: X Lean Operations Course Instructor: Saeed Madjidi, BSIE, MBA Phone: (C) Fax: madjidi@cmtc.com Course Catalog Description: Lean has proven itself in many different manufacturing and service industries to be the dynamic leap in production efficiency needed to excel and survive in the world marketplace. The fundamental principle of Lean is the continuous recognition and elimination of waste in operations and reducing time from order to delivery while maintaining or improving product quality. This course focuses on gaining an understanding of Lean principles, practices, and techniques from both a technical standpoint and the people perspective needed to effect the change and sustain the improvement. Emphasis will be placed on developing the individual skills needed to become a Lean thinker and champion and on building a roadmap for transitioning your organization from its current state to one of being a Lean operation. Classroom sessions will include exercises designed to simulate real world applications to clarify concepts and techniques. Prerequisite: Experience in a manufacturing or service organization and a strong desire and commitment to learn Lean to improve its performance. Location & Meeting Times Wood Land Hills - Northrop Grumman Thursday, October 4th thru December , 5:30-9:00 P.M Course Goals and Objectives: Participants will learn to: Discuss the basic principles of Lean operations Explain and demonstrate Lean tools and techniques Identify waste in production systems Map a current and future state value stream 1

2 Develop a Continuous Improvement (CI) plan for an existing operation Identify steps necessary to implement a Lean system Facilitate teams in making the change to the Lean culture Course Major Topics: Short History of the Industrial Revolution (How we became this way.) What is Lean Manufacturing? What is Waste? The Eight Wastes. What is Value-added Vs. Non Value Added? Standard Work Balanced and Level Flow SMED (Single Minute Exchange of Dies) Set Up Time Reduction Single Piece Flow and Product Cell Design Pull Kanban Systems. Lean vs. Push Manufacturing. JIT (Just In Time) Takt Value Stream Mapping and Spaghetti Charts Transition to Lean Models Lean Implementation Tools Five S, Visual Controls, Andon Signals, Heijunka Boards Kaizen Event Continuous Improvement Poka Yoke (Mistake Proofing), Five Whys (Root Cause Analysis) TPM (Total Productive Maintenance) Required readings: Course Tex(s): Lean Thinking by James Womack and Daniel, Simon and Schuster, 1996 Learning to See by Mike Rother and John Shook, Lean Enterprise Institute, 1999 Handouts: Course Materials Recommended Readings: Lean Transformation by Bruce A. Henderson and Jorge L. Larco, The Oaklea Press, 1999 Toyota Production System by Taiichi Ohno, Productivity Press, 1988 Becoming Lean Inside Stories of U.S. Manufactures by Jeffrey K. Liker, Productivity Press, 1998 A Study of the Toyota Production System From an Industrial Engineering Viewpoint by Shigeo Shingo, Productivity Press, 1989 The Kaizen Blitz by Laraia, Moody, and Hall, Wiley, 1999 Grading Criteria General grading criteria are as follows: A work is of superior quality, unquestionable of the highest level, well beyond any reasonable expectations, demonstrates brilliant 2

3 mastery of the subject matter; B work is of superlative quality showing thorough competence in the subject area, approaching brilliance; C work is well above simply acceptable, going beyond standards, but not striking quality; D work is minimally acceptable, satisfying the stated objectives; F work is unacceptable without satisfying the stated objectives. Final Grade Composition (Approximately): Attendance/Participation 20% Project 30% Mid term Exam 20% Final Exam 30% TOTAL 100% Overall Course Grading Points as a Percentage: Course Standards 90 to 100 = A 80 to 89 = B 70 to 79 = C 60 to 69 = D Below 50 = F The University of California Adult Teaching/Learning Model specifies that in preparation for every course, students will satisfy all prerequisites. During the course itself, all students achieve certain outcomes. All performance assessment depends upon the accomplishment of these outcomes. Students are graded on achievement rather than effort. It is the responsibility of the student to come to class prepared to participate. The University trusts each student to maintain high standards of honesty and ethical behavior. All assignments submitted in fulfillment of course requirements must be the student s own work. All assignments except those designated as group is meant to be individual efforts. Group efforts are meant to be equal efforts by all group members. It is assumed that all students will perform professionally in preparing work required for this class. All assignments must be submitted by their due dates. Late papers will only be accepted when approval is obtained from the instructor prior to the due date. Students are expected to attend all sessions and arrive for class promptly. Students are allowed two absences during each course. Session-By-Session Outline: Topics Introduction to the Course. Introduction to Lean principals and methodology Lean overview with Simulation Activity: Simulation round #1 & #2 Reading Assignment Intro., Chap. 1 &2 3

4 10-11 Introduction to the Course. Introduction to Lean principals and methodology Lean overview with Simulation Activity: Simulation round #3 & #4 Discussion - wrap-up Value Stream Mapping Current State Map Activity: Class exercise, homework, and project kick off Value Stream Mapping Future State Map Activity: Class exercise, homework, and project kick off 11-1 Lean Basic tools: Work place organization and standardization (5s) Plant layout POUS Lean Basic tools: Standard Work. Single Minute Exchange of Dies (SMED) Mid-Term Exam Mid Term Exam, Review VSM class project Kaizen events Measure progress (KPI) Change Management, A Lean Advance tools: Pull/kanban. Activity Class project status Intro., Chap. 1 &2 Learning to See Part 1 &2 Learning To see Part 3 & 4 Chap. 3 & 4 Chap. 5 & 6 Chap. 7& 8 Chap Manufacturing Work cell Five elements of work cell Single piece Flow Cell layout Kanban Systems. Heijunka Boards. Takt time Kaizen event 4

5 Activity Class project status Final Class project presentation Final exam Last day of class 5