Department of Manufacturing Systems Engineering and Management
MSE 507 – LEAN MANUFACTURING
Fall 2015, Tuesday 18:00 to 21:10, JD Room 3520
Ticket Number 15504
Instructor Hamid Gholami, (M.S. – Mechanical Engineering; M.S. – Engineering Management)
Professor of Engineering, Department of Manufacturing Systems Engineering and Management -Department Office: (818) 677-2167
Employment: Vice President of Operations, Accurate Electronics, Chatsworth, CA Faculty E-mail:
[email protected]
MSEM Department Office: JD3310
Telephone: (818) 677-5003
MSEM Department E-mail: [email protected]
Office Hours: Tuesday 18:00 to 19:00 by appointment Website http://www.csun.edu/~hamidg
Microsoft PowerPoint Presentations
There are 8 presentation modules provided on the class website, covering the principles of Systems Engineering and Management. These presentations correspond with the sequence of the chapters and topics covered in the textbooks listed below.
Presentations shall be downloaded and printed as handout (3 slides per page recommended to allow you to take notes next to the slides during class sessions) Textbook 1. Womack, James P. and Jones, Daniel T. (2003). Lean Thinking : Banish Waste and
Create Wealth in Your Corporation New York: Simon & Schuster. ISBN: 0-7432-4927-5 2. Productivity Press; 1st edition (1999). Cellular Manufacturing: One-Piece Flow for
Workteams (Shopfloor Series). Productivity Development Team. ISBN: 156327213X Additional
Readings 1. Tapping, Don, Shuker, Tom, and Luyster, Tom. (2002). Portland: Productivity Press Value Stream Management. 2. Henderson, Bruce A., Larco, Jorge L. and Martin, Stephen H. (1999). Lean Transformation: How to Change Your Business into a Lean Enterprise. New York: The Oaklea Press
3. Suri, Rajan. (1998). Quick Response Manufacturing: A Companywide Approach to Reducing Lead Times. Portland: Productivity Press
4. Liker, Jeffrey. (1998). Becoming Lean: Inside Stories of U.S. Manufacturers. Portland: Productivity Press
5. Jackson, Dr. Thomas L. (1996). Implementing a Lean Management System. Portland: Productivity Press
6. Mahoney, R. Michael, CPIM and Plossl, George W. (1997). High-Mix Low-Volume Manufacturing. Hewlett-Packard Professional Books
7. Hirano, Hiroyuki. (1999). 5S for Operators: 5 Pillars of the Visual Workplace. Portland: Productivity Press
Background
and Purpose Lean is defined as the elimination of waste. This class will discuss the basic principles of lean (value, A key attribute of the technical professional is his/her emphasis on and interest in professional values and goals rather than those of an organization. The technical value stream,
flow, pull, and perfection) and compare and contrast lean with the Theory of Constraints and Quick Response Manufacturing.
Lean thinking principles are emerging as a method to improve the flexibility, reliability, and profitability of enterprises worldwide. Lean thinking is being used to reduce setup times, lot sizes, and inventories. Lean is all about removing waste in the enterprise. This includes waste in time as well as cost. As enterprises have reduced costs and improved quality, the primary competitive measure is the ability to respond to the customer. This class presents an overview of lean manufacturing concepts and introduces methods and tools designed to put these concepts to work in a manufacturing environment.
General Course Structure
There are three learning activity tracks that run in parallel throughout this course.
One track entails presentations and discussions of topics particularly pertaining to systems engineering and management.
A second track involves reading assignments, exams (multiple-choice, true & false and write-up essays), and discussions addressing the lean manufacturing concept and elimination of waste. The third track is the team development of a lean manufacturing project. By the fifth or sixth
week of the semester, the instructor will establish teams consisting of 3-5 members each. Note: Only the term project will be a team effort. All other course tasks and requirements
(exams, assignments, etc.) are done solely on an individual basis. The manner in which this course is structured is such that active participation of all class members throughout the semester is essential.
COURSE PROPOSED PLAN
Notes:
1) Tentative schedule: dates/assignments/topics covered may change as deemed necessary.
2) Exam time slots will be announced as the semester progresses.
Week 1 Introductions - to the instructor, class members, and the course Presentation – Introduction to Lean Manufacturing
Reading Assignment: Lean Thinking Chapter 1 – Value (pp. 29-36)
Week 2 Presentation – Chapter 1 - Value
Reading Assignment: Lean Thinking Chapter 2 – The Value Stream (pp. 37-49)
Week 3 Presentation – Chapter 2 – The Value Stream
Reading Assignment: Lean Thinking Chapter 3 – Flow (pp. 50-66)
Week 4 Presentation – Chapter 3 – Flow
Reading Assignment: Lean Thinking Chapter 4– Pull (pp. 67-89)
Week 5 Presentation – Chapter 4 – Pull
Reading Assignment: Lean Thinking Chapter 5– Perfection (pp. 90-98)
Week 6 Presentation – Chapter 5 – Perfection
Week 7 Mid Term Exam
Week 8 Presentation: 5S – The Visual Workplace
Week 9 Presentation – Cellular Manufacturing Chapters 1 & 2
Week 10 Presentation – Cellular Manufacturing Chapters 3 & 4
Week 11 Presentation – Learning to see (Value Stream Map part 1)
Week 12 Presentation – Learning to see (Value Stream Map part 2)
Week 13 Chapter 11, From Lean Thinking – An Action Plan
Week 14 Research Assignment Project presentations
Week 15 Final Exam: Lean Manufacturing, 5S, Value Stream Mapping, Kaizen 12/15/15
RESEARCH ASSIGNMENTS DESCRIPTIONS
Research Assignment One: Lean Manufacturing
Research the lean initiatives taken by the leadership team at the employers of one of the partnership members.
Compile examples of key steps used in the process.
Prepare step-by-step summaries of key steps taken by each employer to increase value and become lean in the manufacturing, engineering, and administrative functions.
For each process, identify and summarize the nature of the decision-making authority and the responsibilities of the manager who will supervise the lean activities.
Summarize the primary similarities and differences among the processes and the manager’s authority and responsibilities between each employer of partnership members.
Deliverables:
Present (maximum 20 minutes) a summary of research findings to class on Week 14
presentation order will be randomly assigned.
Distribute copies of written report summary to all class members at the time of the presentation, and submit complete report to instructor on Week 11.
Submit Partnership Peer Review Reports (one from each class member) on Week 14.
Research Assignment Two: 5S
Seek out at least two publicly available references that address at least one case of standardizing the workplace using 5S methodology.
Summarize the process provided in the reference.
Research the 5S process for professional employees at the employer of one of the partnership members.
Acquire copy of 5S audit forms (if any exist) used as part of the employer’s process.
Prepare a step-by-step summary of the key steps in the employer’s process of 5S implementation.
Critique the employer’s process in the context of the reference selected.
Critique the performance evaluation form in the context of the employer’s process.
Deliverables:
Present (maximum 20 minutes) a summary of research findings to class on Week 14; presentation order will be randomly assigned
Distribute copies of written report summary to all class members at the time of the presentation, and submit complete report to the instructor on Week 14.
Submit Partnership Peer Review Reports (one from each class member) on Week 14.
Research Assignment Three: Kaizen Blitz
Seek out and summarize at least two publications that address Kaizen Blitz (i.e. Rapid Change) processes.
Based on the publications researched, class handouts, and other sources as appropriate, identify at least two productive approaches to ensure successful completion of a Kaizen.
Research and summarize Kaizen processes for professional employees at the employer of one of the partnership members.
Acquire copies of primary Kaizen preparation/execution forms used as part of the employer’s process (if any exist).
Evaluate the role(s) of a professional value stream manager in the Kaizen processes of the organization.
Deliverables:
Present (maximum 20 minutes) a summary of research findings to class on Week 14; presentation order will be randomly assigned
Distribute copies of written report summary to all class members at the time of the presentation, and submit complete report to the instructor on Week 14.
Submit Partnership Peer Review Reports (one from each class member) on Week 14.
Research Assignment Four: Using the Tools
The theme for this assignment is implementing lean operations – in the department where you work, someone else’s department, or in an organization you are familiar with or worked for before. Within this theme, project partners should identify and propose their own applied research assignment.
Deliverables:
Present (maximum 20 minutes) a summary of research findings to class on week 14; presentation order will be randomly assigned.
Distribute copies of written report summary to all class members at the time of the presentation, and submit complete report to the instructor on Week 11 .
Submit Partnership Peer Review Reports (one from each class member) on Week 14.
STANDARD OPERATING PROCEDURES
1. Class members are encouraged to maintain personal and professional standards consistent with The Fundamental Principles of the Code of Ethics of the Accreditation Board for Engineering and Technology:
Engineers uphold and advance the integrity, honor and dignity of the engineering profession by:
o Using their knowledge and skill for the enhancement of human welfare;
o Being honest and impartial, and serving with fidelity the public, their employers and clients;
o Striving to increase the competence and prestige of the engineering profession; and o Supporting the professional technical societies of their disciplines.
2. Withdrawing from (dropping) this course should be accomplished during the first two weeks of instruction. Please note that failure to officially drop any course results in a grade of U, which is the equivalent of an F for your transcript and grade point average.
3. It is a University requirement that all undergraduate and graduate students must pass the Writing Proficiency Examination (WPE) as part of earning their degree. Graduate students must pass the WPE before completing more than 12 units in their graduate program. Students who earned an undergraduate degree at CSUN in Spring 1982 or thereafter have already met the requirement. Delaying the completion of the WPE requirement can delay your graduation. For additional information, see FAQs at www.csun.edu/~msem, or contact your academic advisor.
4. It is a University requirement that all graduate students whose overall undergraduate degree grade point average was less than 3.0, and who have not taken the General Aptitude Test of the Graduate Record Examination (GRE), must take the test before completing more than 12 units in their graduate program. A delay in meeting the GRE requirement will delay your classification and can delay your graduation. Information on the test is available at www.gre.org or at FAQs at www.csun.edu/~msem, or by contacting your academic advisor.
5. The major of each student in this class will be verified using the University course roster. Students whose majors are not correct must submit a change of major within the first three weeks of the semester. Graduate students should submit a Change of Objective for Graduate Students to the MSEM Department Office. The form can be obtained from FAQs at www.csun.edu/~msem, or by contacting your academic advisor.
6. The classification status of each graduate student in this class will be verified using the University course roster. Conditionally classified graduate students who are eligible for classification must submit a Request for Classification during the first three weeks of the semester. Eligible students are in the correct major and in GRAD status, have met their WPE and GRE requirements, and have a GPA of 3.0 or better. . For additional information, see FAQs at www.csun.edu/~msem, or contact your academic advisor.
7. Class members are to rely on emails (the secondary method of communication) for all postings pertaining to the course. All students are expected to ask questions in class (first method of communication) and fully participate in the class discussion, So that all students will benefit from the answers.
8. Class members are to be considerate and respectful of their colleagues, particularly in regard to the project assignment, team effort and presentations.
9. Class members are responsible for material in reading assignments, class presentations and group discussions.
10.Budgeting 5-6 hours per week for this course, in addition to class participation, is not unreasonable.
11.Class members are expected to prepare and participate constructively in group discussions and team meetings.
12.The Mid Term and Final Exams format will be essay write-ups
13.All graduate students majoring in MSEM Department programs (i.e. Automation Engineering, Engineering Management, Materials Engineering) are encouraged to add their e-mail addresses to the Department listing. This listing is used for special notifications (e.g. course scheduling changes, academic advisement notices, social events, and emergencies). The list may be accessed at www.csun.edu/~msem/faqs.htm or by e-mailing a request to [email protected] to be added to the list.
14.Cheating on the exams will result in no credit for the exam in question, and you will be referred to the college administration. This is university policy and there will be no exceptions. All students should be aware that even one incident of academic dishonesty may also merit expulsion from the University.
15.Tardy submissions are unacceptable to the instructor and unfair to other class members. Professionalism dictates timely submission of the project report.
COURSE EVALUATION STRUCTURE
30 % Mid-Term exam
10 % Homework assignments
25 % Team Research Project
Team score and Individual Contribution
o Team Formal Written Report on project topic
35 % Final Exam – Comprehensive (multiple choice, true/false and write-up questions). o Covers all reading assignments, discussion and lecture material.
o
Duration: 2 hoursLetter-Grade Scale
A ≥ 94 90 ≤ A- < 94
88 ≤ B+ < 90 83 ≤ B < 88 80 ≤ B- < 83 75 ≤ C+ < 80 70 ≤ C < 75 68 ≤ C- < 70 60 ≤ D < 68
F < 60
Note: Plus/Minus Grading WILL BE USED for this course.
