Syllabus ENVR E-137 Sustainable Manufacturing and Supply Chain Management Operations Fall 2014 (4 Credits) CRN (14010)

Transcription

1 Syllabus ENVR E-137 Sustainable Manufacturing and Supply Chain Management Operations Fall 2014 (4 Credits) CRN (14010) Instructor: Ramon Sanchez, ScD. Assistant Director Sustainability and Environmental Management Program Harvard Extension School Director of Corporate Outreach and Strategy Center for Health and the Global Environment Harvard School of Public Health Class times: Tuesdays beginning Sept. 2, 7:40-9:40 pm. Optional sections to be arranged Online option available Class isite: This course provides a set of tools and skills to identify, evaluate, and improve the sustainability of manufacturing and supply chain operations. It enables students to understand core concepts of industrial and commercial activities, in this way they will be able to design sustainable manufacturing, service and supply chain operations. Students will learn: - How to use continuous improvement techniques and value stream mapping to reduce waste and environmental impacts while reducing costs. - How to plan retrofits and capital investments in current and future productive operations to reduce environmental impacts - How to manage a product development or new product introduction process from conceptual design to large-scale manufacturing while reducing its environmental impacts - How to design a production floor layout to reduce the environmental footprint for any product - How to evaluate suppliers sustainability in an objective way and how to use this information to assign purchasing contracts and to negotiate joint research programs to reduce the environmental footprint of products - How to manage transportation logistics and suppliers to keep low inventories and save energy by reducing the need for warehouses inside the company - How to design and manage a vendor management program to reduce delivery lead times, costs and environmental impacts while improving overall quality of the company s products. - Practical techniques to reduce energy usage, raw materials, work-in-process, down times, overproduction, etc. - How to operate and manage a manufacturing facility for any product and/or how to run a warehouse to reduce environmental damages - How to select materials for products or processes to reduce environmental impacts by design (by using "green chemistry") 1

2 - How to estimate the right level of automation for each product line based on market stability and product's complexity, this helps to keep capital costs low, but also helps in reducing the "legacy" environmental footprint caused by machinery and other capital goods - How to reduce human environmental exposures in an industrial environment - Techniques for efficient materials' handling inside the company in order to reduce the need for conveyors, forklifts and carts (which reduce the overall environmental impacts of the operation) - How to do "reverse-engineering" and design changes to improve products sustainability Teaching Fellows: Raphael Arku, MSc. Candidate for the Doctor of Science Degree in Environmental Health Harvard School of Public Health rarku@hsph.harvard.edu Required Textbook: Liker, Jeffrey. "The Toyota Way: 14 Management Principles from the World's Greatest Manufacturer". McGraw-Hill, 2004 Recommended books: Ingrassia, Paul and White, Joseph. Comeback: The Fall and Rise of the American Automobile Industry. Simon & Schuster, Womack, James and Jones, Daniel. Lean Thinking: Banish Waste and Create Wealth in Your Corporation, Revised and Updated. Free Press (a division of Simon & Schuster), Palevich, Robert. "The Lean Sustainable Supply Chain: How to Create a Green Infrastructure with Lean Technologies". FT Press, 2012 Session 1, September 2, Introduction to the Course - A brief history of manufacturing, commerce and sustainability Session 2, September 9, The extended value stream process: From conceptual design to the final customer - Basic concepts on strategic planning of manufacturing and supply chain operations - Strategic considerations: Manufacturing VS Outsourcing Session 3, September 16, Types of production systems and their relationship to capital expenditures and sustainability - Introduction and basic principles of the Toyota Production System 2

3 - Principles for selecting the right level of automation in manufacturing and warehousing operations Session 4, September 23, Case Study: NUMMI, a joint venture between GM and Toyota in American soil o See how Toyota learned how to adapt its Lean Production System to American suppliers, government regulations and labor practices o See how GM got exposed to a new production system, difficulties in changing GM s decades-old corporate culture and how investments in state-of-the-art facilities aren t everything when maintaining global competitiveness - Homework 1 is assigned Session 5, September 30, Chronology on the manufacturing and supply chain landscape in the past 2 decades and how this relates to job creation and sustainability - Potential health and environmental effects of international trade and manufacturing operations - Principles of pollution prevention, industrial ecology, environmental and life-cycle assessments - Recommendations for risk management in manufacturing and supply chain operations - Homework 1 is due Session 6, October 7, Description of types of waste in manufacturing and supply chain operations - First step for sustainable operations: Value Stream Mapping - Importance of keeping a multi-bottom line approach in any organization - Midterm Project is assigned Session 7, October 14, Workplace organization, basic definitions and importance - Relationship between workplace organization, inventory levels and sustainability - Basic techniques to implement an appropriate workplace organization to reduce inventories, improve quality of manufactured goods and expedite customer service Session 8, October 21, Principles for designing the lay-out of a manufacturing operation or warehouse - Equipment features and practices to enable flexibility in the use of the production and/or warehouse floor - Environmental and economic effects of changing from a functional to a product-oriented lay-out in a manufacturing operation or warehouse - Some logistical benefits of a proper lay-out for your operations Session 9, October 28, Principles for flexible and agile manufacturing o One-piece-flow o Just-in-time (JIT) o Single Minute Exchange of Die (SMED) 3

4 o Workstation design and ergonomics o Card signaling system (Kanban) o Fool-proof systems (Poka-Yokes) - Analogies on how flexible and agile manufacturing systems can be used in warehousing and distribution operations - Environmental effects of having a flexible operation - Midterm Project is due Session 10, November 4, A brief description of a New Product Development or New Product Introduction Process - Sustainable materials and green chemistry in product design - Importance of the integration between manufacturing and product design (modular design, design for manufacturing guidelines, pilot runs, rapid integration of new products into the production lines, etc.) - Lessons learned from managing a product development and a manufacturing area at the same time - Recommendations when creating and managing a new product development process - Environmental and economic effects of a good new product development process - Homework 2 is assigned Session 11, November 11, The concept of Continuous Improvement - Importance and some recommendations on how to implement a continuous improvement project - Recommendations to enhance employee involvement in any continuous improvement project - Some recommended practices when implementing a continuous improvement project - Relationship between continuous improvement and sustainability - Homework 2 is due Session 12, November 18, The Supply Chain and the concept of Extended Enterprise - Basic components of a Supply Chain - Recommendations for an effective Supply Chain Management - Some operational practices to enhance operational flexibility (supply agreements, on-time delivery clauses, Vendor Managed Inventory, etc.) - Final Project is Assigned Session 13, November 25, Operational Considerations: Manufacturing VS Outsourcing - Technical and financial considerations when selecting a vendor - Environmental and sustainability considerations when evaluating or selecting a vendor - Recommendations for effective outsourcing (with national and international suppliers) - Sustainability implications of outsourcing 4

5 Session 14, December 2, Concept of Value Engineering Projects - Management of reverse engineering and value engineering projects - Monitoring of cost and environmental savings due to value engineering projects - Game on Sustainable Manufacturing and Supply Chain Operations Session 15, December 9, Final Presentations - Final Project is due Session 16, December 16, Final Presentations Grading: Homework (20%) Each homework is worth 10% of final grade Midterm Project (35%) Final Project (35%) Final Presentation (10%) 5