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1 IME 5050 Continuous Improvement in Operations (CIO) IME 5050 Continuous Improvement in Operations (CIO) Spring 2011 Tuesday (6:00p – 9:20p) Prof. Tarun Gupta ([email protected]) Office: E220 Parkview Campus (Ph. # 276-3361) Catalog Description: The purpose of this course is to introduce business and engineering students as well as managers to the process of kaizen (Continuous Improvement) and Total Employee Involvement. Objective: Introduce Continuous Improvement, Lean Manufacturing, Kanban, JIT and Quick Response Manufacturing (QRM) as it applies to manufacturing systems to the extent that the participants can practice these approaches in real world situations. A closer review of Toyota Production System is newly added this semester. Pre-requisites: Graduate standing. Open to upper class and graduate students. Required Textbooks: Toyota Production System – 3rd Edition, Yasuhiro Monden, Chapman Hill Publication, ISBN 0-412-83930-X. Recommended Textbooks: 1. Automation, Production System and Computer Integrated Manufacturing, Mikell Groover, Latest Edition, Prentice Hall. 2. Factory Physics, Foundation of Manufacturing Management, Wallace J. Hopp & Mark L. Spearman, Edition 2, IRWIN 3. Lean Enterprise Systems – Using IT for Continuous Improvement, by Steve Bell, Wiley Sons, Editor Andrew Sage, 2006 edition. 4.. Other materials – from a list of websites http://www.industrialtimestudy.com/lean.html http://www.s3co.com/glossary/W2 en.wikipedia.org/wiki/Lean_manufacturing www.leanmanufacturingconcepts.com/; www.lei.org; Week # Jan. 12 Topics: Readings 1. Introduction, Background and Global Market, Competition & Lecture Manufacturing Environment, Continuous Improvement Philosophy –Projections for 2020 (Video clip), Manufacturing cell design Dimensions of CIO – Philosophy & mindset (Relentless pursuit to Perfection) 2&3. Definitions – Gemba, JIT, Kanban, Poke-Yoke vs. Baka-yoke, Ch 2 & 3 Jidoka, Heijunka, Kaizen, Kaikaku, Jishuken, VSM (Value-Stream Ch 7 Mapping), Genchi Genbutsu, Hansei, PDCA, Lean Production, Case Study 1 5S, 3P, 4M, 3M (Muda, Mura, Muri), PDCA, TPS, TPM. (Paper #s 1 , 2 (Week 3)) February 4. Quick Response Manufacturing (QRM) – Cost, Quality & Delivery – Ch 4 Three dimensions of competitive advantage (Paper # 3) Case Study 2 1 5. Continuous Improvement Matrix (Design, Order Taking, Production) – Concepts & Underlying Philosophy, Tools & Techniques: Product Life Cycle (Paper #4) Ch. 5 6. Manufacturing Lead Time, Work-in-progress, Capacity, Utilization, Cycle Time vs. Takt Time, Just-In-Time vs. Kanban. - Visual Control, Communication across levels horizontally and vertically in the organization. Calculation for # of Kanban cards (Paper #5) 7. Mid Term Forecast vs. Make-to-orders from end-customer, retailer and distributor, Level Demand & Level Scheduling (Heijunka), March 8. Level Scheduling & Sequencing, Lean Consumption, Six-Sigma and QFD (Paper #6) Case Study 3 9. Five Steps – (a) Identify Value as defined by the customer (Paper #7) (b) Establish Value Stream (c) Establish Flow (d) Introduce Pull (e) Strive for Perfection 10. Hoshin Kanri – Policy Deployment, Cost Accounting Methods (Paper #8) Ch. 10 Semester Project Presentations I: Level of Automation, Implementation Policy 11. Semester Project Presentations II: Lean Production, Lean Consumption, Lean Provision - Customer, Company and providers – Win-win-win situation for ALL three partners for a happy solution April 12. Final Exam, April 6 (6:00 – 8:00 p) Semester Project: A group of up to 4 students will identify a suitable problem to tackle as a team semester project following the domain knowledge and principle derived from the class. A half-page synopsis is due in two weeks on January 23 at the class time. Each team is expected to submit a report in an acceptable format (the format will be discussed & posted by January 23). Finally the team will be scheduled for an in-class presentation on one of the two days as per the course outline. Two Exams: Midterm & a Final Exam – The exams will be closed books and notes. A list of formulas as applicable can be recorded on an 8” x 11” sheet of paper one-sided. There will be in-class activities roughly once every four weeks. A more firm schedule will be provided during the semester. 2 .
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