Habib University Continuing Education Series: Lean Engineering

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1 Habib University Continuing Education Series: Lean Engineering

2 ABOUT HABIB UNIVERSITY Habib University is a unique liberal arts and sciences university, offering interdisciplinary education in science, engineering, arts, humanities and social sciences. It has been established in Karachi under the patronage of the House of Habib. Committed to providing the highest standards of excellence in higher learning, the University has several formal partnerships including one with Texas A&M University at Qatar. Habib University is a preeminent institution of higher learning, dedicated to enriching individual lives and engaging society through teaching, research and service. Its mission is to educate promising students from all backgrounds and enable them to become competent, caring and critically-conscious members of society. Habib University engages outstanding academics who work with us to enrich the minds and lives of our students, fostering an environment that promotes creativity, academic freedom and an exchange of ideas.

3 CONTINUING EDUCATION The need for continuing education in the 21st century s knowledge-based economy is paramount. Knowledge and technology are at the heart and mind of the global economy. The country s success in the knowledge-based economy depends on the ability of its workforce to respond to new challenges and pursue lifelong learning opportunities. Habib University s Office of Research and Continuing Education aims to provide state-of-the-art continuing education courses to fulfill the growing demand for a highly skilled work-force. By providing this essential service we intend to bridge the gap between the needs of the society and the economy. At Habib we have forged collaborations with leading international universities such as Texas A&M University at Qatar and Carnegie Mellon University, USA and hired highly skilled faculty with diverse national and international backgrounds including the United States, United Kingdom, Germany, and Russia. Our international collaborations and highly qualified faculty allow us to provide courses unlike any other institution. These courses can be arranged in-house at our state-of-the-art campus located in the heart of Karachi as well as Doha and Dubai, depending upon your corporate needs. To help you get the best return on your corporate training investment, Habib University s Office of Research and Continuing Education can facilitate a needs assessment, and provide proven programs and customized training. ORCE programming staff have extensive experience in adult education, and the instructors are experts in their fields. Together, they can provide you with proven course content and expert delivery that meets your organization's training needs. For further information contact Habib University s Office of Research and Continuing Education at orce@habib.edu.pk or visit our homepage at

4 WHAT IS LEAN ENGINEERING? Lean is a philosophical approach to developing flexible, responsive processes capable of providing your customers with what they want, in the amount they need, exactly when they want it. FUNDAMENTAL PRINCIPLE OF LEAN Anything that does not add value to the product is waste and must be reduced or eliminated. An average company wastes 85% of its productive time on non-value added work. Henry Ford was able to mine ore on Monday and, using that very same iron ore, produce a car coming off the assembly line on Thursday. He did this by focusing on the total elimination of non-value adding wastes. LEAN PRINCIPLES 1 1. Specify value in eyes of customer. 2. Identify value stream and eliminate waste. 3. Make value flow at pull of customer. 4. Involve & empower employees. 5. Continuously improve in pursuit of perfection. 1 Origin: Toyota Production System (TPS)

5 LEAN SYSTEMS 1. WORK TO TAKT TIME 2. ONE-PIECE-FLOW 3. AT THE PULL OF THE CUSTOMER HISTORY OF LEAN 1850 American Civil War ELI WHITNEY Interchangeable Parts Drawing Conventions Tolerances Modern Machine Tool Development FREDERICK TAYLOR Standardized Work Time Study & Work Standards Worker/Management Dichotomy ELI WHITNEY 1900 FRANK GILBERTH Process Charts Motion Study FREDERICK TAYLOR Great War HENRY FORD Assembly Lines Flow Lines Manufacturing Strategy FRANK GILBERTH 1950 World War VII EDWARD DEMING, JURAN SPC TQM EIJI TOYODA, TAICHI OHNO Toyota Production System Just-in-Time Stockless Production World Class Manufacturing HENRY FORD LEAN MANUFACTURING TAICHI OHNO 2000 SHINGO

6 WHY LEAN? The World is Shrinking... The Competition is Growing...

7 LEAN HELPS TO QUICKLY LEVERAGE COMPANY STRENGTHS THE COMPETITION IS NOT STANDING STILL Sales Growth Simultaneously Reduce Operating Costs Preserve Access to Market Grow Domestic Business Develop new products STRATEGY FOR DEPLOYMENT Start in Manufacturing (Office Lean will follow) Identify improvement pilot project Train Core teams in Lean methods and techniques (Learn by doing) Increase formally trained Lean Transfer people in the company Report Monthly with Radar Charts/Success stories

8 IN THIS LEAN COURSE YOU WILL LEARN Process improvement techniques that reduce or eliminate non-value added work. This in turn makes processes more efficient in your enterprise, improving productivity & hence profitability, providing you with a competitive edge in your industry. SO, WHAT DO WE NEED TO DO TO SUCCEED? SPEED MONTHS DAYS HOURS YOUR COMPANY GOALS COST REDUCE FLOOR SPACE LOWER INVENTORY VISUAL CONTROLS AND DISPLAYS CREATE A FLEXIBLE WORK FORCE

9 FOCUS IS ON GENERATING A THOROUGH UNDERSTANDING OF LEAN TOOLS AND HOW TO APPLY THEM IN THE REAL OR PRACTICAL WORLD Conducting class Kaizens on various projects Creating VSM or value stream mapping Understanding of the DMAIC process Utilizing 6S Awareness of 8 types of waste Distinguishing between value added, non value added & necessary evil Reducing change over /set up time by implementing SMED Creating a visual work place Kanban Implementing the pull system Undestanding of takt time, lead time, cycle time Defect prevention techniques aso known as Jidoka Line balancing also known as Heijunka Creating standardized work or repeatible & stable work practices The value of TPM or total productive maintanance Intro to learning curves Pareto charts Cause and effect diagrams or fish bone diagrams WHO NEEDS LEAN & SHOULD LEARN LEAN In a competitive world with a global economy all company employees need lean from the CEO all the way to the factory floor worker. Encompassing the entire enterprise environment including office workers, as we do not want to build only islands of Lean.

10 COURSE INFORMATION COURSE INFORMATION: Register at: Registration Fee: Rs (payable on the day of the event) Saturday, March 14th, 2015, 10:00 a.m. to 3:00 Habib University City Campus OFFICE OF RESEARCH AND CONTINUING EDUCATION SCHOOL OF SCIENCE AND ENGINEERING

11 COURSE INSTRUCTOR Mr. Mateen Haider is a process improvement/lean Engineering specialist, whose forte is interfacing Lean theory with the practical world. His educational background includes a BS in Mechanical Engineering and an MS in Industrial/Lean Engineering. He is also a Certified Six Sigma, Black Belt. The majority of his 37 year career has been in the US Aerospace Industry improving productivity. With a focus on reducing or eliminating non value added activity. His experience has mainly been in the efficient production of aero structures, where a high degree of accuracy is required. Aero structure areas/shops that he has supported & managed include the sheet metal, machine, composites, processing & assembly. Programs that he has supported include: Boeing's 777, 767, 757, 747 & C-17. Lockheed's C-5, Fairchild's A-10, Grumman's A-6, Rockwell's B-1B & Space Shuttle, Sikorsky's Blackhawk & Seahawk, Kaman's SH-2 G & KMAX, GE's CF-6 Thrust reversers. He also teaches Lean Engineering at the college level in Connecticut & consults on the subject. His titles have included Director of Operations, Manager of Industrial/Lean Engineering, Manager of Manufacturing Engineering (ME). In his position as Manager of ME he was responsible for responding to requests for quotes (RFQ's) all the way to producing the product. His voluntary activities include heading, The Citizens Foundation chapter in Connecticut, his Rotary District's scholarship committee, the Institute of Industrial Engineering Chapter 075 MA & CT. For his voluntary activities he also received the state of Connecticut's Immigrant of the Year award for 2010 & a Paul Harris from Rotary. Has great communication skills and is multi lingual in Urdu, Punjabi, English & German.

12 Habib University: Block 18, Gulistan-e-Jauhar, University Avenue, Off Shahrah-e-Faisal, Karachi. habib.edu.pk facebook.com/habibuniversity twitter.com/habibuniversity