Lean manufacturing is a systematic approach to minimising waste in a manufacturing system, by focusing on the activities that add the most value through the eyes of the customer. The basis of lean manufacturing originated in the car industry and was developed by Toyota in Japan. Lean is now used extensively worldwide, in all types and size of organisation, to improve international competitiveness. It is therefore crucial for manufacturing engineers to be able to design and operate manufacturing systems that employ lean successfully.

The aim of this unit is to introduce students to the principles and processes of lean manufacturing, so that they can become an effective and committed practitioner of lean in whatever industry sector they are employed in. To do this, the unit will explore the tools and techniques that are applied by organisations practising lean. The students will consider both the benefits and challenges of using lean manufacturing, and become sufficiently knowledgeable about the most important process tools and techniques to be able to operate and use them.

Among the topics included in this unit are: scoping and defining lean manufacturing, the benefits and challenges of adopting Lean, The Toyota Production System (TPS), common tools and techniques associated with lean manufacturing and process improvement, and the most appropriate improvement tool(s) to tackle a problem.

On successful completion of this unit students will be able to explain the common principles of lean manufacturing, compare the Toyota Production System with the now more widely adopted generic approaches to lean manufacturing, utilise a range of the process improvement tools used within lean manufacturing, and demonstrate effective communication skills in order to lead the process of continuous improvement across an organisation.

Scoping and defining lean manufacturing:
The common principles of lean manufacturing philosophy
Origins of lean
Defining lean and its importance to the customer
Identifying and eliminating material and process waste that adds no value from the customer’s perspective

Benefits and challenges of adopting lean:
Why an organisation would consider adopting a lean philosophy
Productivity, quality, customer satisfaction, delivery performance
The benefits of a lean organisation to the customer, the employees, and the shareholders
Outline the benefits of lean in terms of cost, quality, delivery, customer satisfaction, management complexity and cost to serve
Challenges of implementation: change management, managing expectation, empowerment, motivation, ‘burning platform’, investment, supply chain

Toyota Production System:
Research the Toyota Production system (TPS) and identify the fundamental elements of the TPS and the motivation behind creating the TPS
Compare TPS with the recognised theory and production systems publicised by other global manufacturers: how do they differ and how they are similar?
How the common principles are now being adopted outside manufacturing

Common tools and techniques associated with lean manufacturing and process improvement:
Seven Wastes, continuous flow, kanban (pull System), just-in-time (JIT), lean simulation activities, value stream mapping, Poke Yoke, 5 Whys (Root Cause Analysis), Total Preventive Maintenance Plan-do-check-act (PDCA), Single Minute Exchange of Die (SMED), A3 Reporting, Visual Management

Selecting the most appropriate improvement tool to tackle a problem: Tools for improving quality and delivery

Communication:
Facilitate a small group in the application and use of one of the lean tools (e.g. 5 Whys technique, A3 Report)
Identify factors that influence engagement within a group, facilitation skills and change management.

A 15 minute (plus Q&A) presentation analysing and reflection on lean manufacturing, assessing learning outcomes 1 and 2, weighted 50%.

A 1500 word individual analytic and reflective report assessing learning outcomes 3 and 4, weighted 50%.

Whole group lectures will be used to deliver new material and to consolidate previous material. Small-group tutorials, with activities designed to enhance the understanding of the material delivered in the lectures, will be used to apply the skills and knowledge learned. A mixture of classroom based and practical activities will take place supported by staff.

Examine the common principles of lean manufacturing and how the implementation of a lean production system contributes to business success.

Evaluate the Toyota Production System against the now more widely adopted generic approaches to lean manufacturing.

Specify a range of the process improvement tools used within lean manufacturing.

Demonstrate effective communication skills in order to lead the process of continuous improvement across an organisation.

PCs with standard office and engineering software

BICHENO, J. and HOLWEG, M. (2009) The Lean Toolbox. 4th Ed. PICSIE Books.
LIKER, J. and MEIER, D. (2006) The Toyota Way Fieldbook. McGraw-Hill.
WOMACK, J., JONES, D. and ROOS, D. (1990) The Machine That Changed the World. Free Press.

Must be registered on HNC/D Mechanical Engineering provision at South Staffordshire College.

Lean manufacturing is a systematic approach to minimising waste in a manufacturing system, by focusing on the activities that add the most value through the eyes of the customer. The basis of lean manufacturing originated in the car industry and was developed by Toyota in Japan. Lean is now used extensively worldwide, in all types and size of organisation, to improve international competitiveness. It is therefore crucial for manufacturing engineers to be able to design and operate manufacturing systems that employ lean successfully.

The aim of this unit is to introduce you to the principles and processes of lean manufacturing, so that you can become an effective and committed practitioner of lean in whatever industry sector you are employed in. To do this, the unit will explore the tools and techniques that are applied by organisations practising lean. You will consider both the benefits and challenges of using lean manufacturing, and become sufficiently knowledgeable about the most important process tools and techniques to be able to operate and use them.

Among the topics included in this unit are: scoping and defining lean manufacturing, the benefits and challenges of adopting Lean, The Toyota Production System (TPS), common tools and techniques associated with lean manufacturing and process improvement, and the most appropriate improvement tool(s) to tackle a problem.

On successful completion of this unit you will be able to explain the common principles of lean manufacturing, compare the Toyota Production System with the now more widely adopted generic approaches to lean manufacturing, utilise a range of the process improvement tools used within lean manufacturing, and demonstrate effective communication skills in order to lead the process of continuous improvement across an organisation.