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Module Code - Title:


Year Last Offered:


Hours Per Week:













Grading Type:


Prerequisite Modules:

Rationale and Purpose of the Module:

This module will explain the concepts behind the Lean tools, and will examine the various elements involved in effectively using these tools to support the organisation's Lean transformation. The aims of this module are: 1. To describe what Lean actually means, 2. To inform you of its contextual perspective, and 3. To provide you with a working knowledge of many of the main tools available within the Lean toolbox.


1. [Introduction to Lean management] Overview of lean principles, tools and techniques; History and evolution of Lean; The Toyota Production System 2. [Value stream mapping] process mapping, observation, flow charting, Value Add and Non Value Add, Identification and elimination of waste. Developing the current and future state. 3. [Workplace organisation & Standard Work] Takt Time, Cycle Time, Standardising Processes, batch size, Process Capacity Analysis; Line Balancing. 4. [Pull Systems] Just in Time, Single Piece Flow, Cell Design and Cellular Flow; Kanban, 'Pull' verses 'Push' Systems 5. [Kaizen, SMED (Single Minute Exchange of Dies) & 5S] Rapid improvement methodologies; Evolution - Kaizen Vs Revolution û Kaikaku; Set-up Reduction using SMED Methodology; 5S Creating and sustaining an orderly work environment: Seri, Seiton, Seiso, Seiketsu, Shitsuke 6. [Lean Supply Chain] Supplier management, relationships and partnering, Configuration and Logistics management, Demand Amplification Mapping û The Bullwhip Effect.

Learning Outcomes:

Cognitive (Knowledge, Understanding, Application, Analysis, Evaluation, Synthesis)

On completion of the module, the student should be able to: 1. Discuss the evolution of Lean 2. Identify and explain the differences between Mass Production and Lean models 3. Define the main elements and concepts of the Toyota Production System 4. Identify how to perform VSM and develop implementation plans 5. Describe the elements of Standard Work and identify the process and tools to develop and implement Standard Work 6. Describe the importance and operating rules of Kanban systems, define their functions and explain how they work 7. Define Load Levelling and describe the steps to implementing such a system 8. Apply the techniques of Single Minute Exchange of Dies (SMED) 9. Define how to successfully implement and sustain 5S 10. Describe the requirements for successful cell design 11. Differentiate between various cell design options 12. Identify how to effectively plan Kaizen events 13. Explain the importance of post-Kaizen activity to sustain improvements

Affective (Attitudes and Values)

Understand the strategic role of process improvement in organisation success

Psychomotor (Physical Skills)


How the Module will be Taught and what will be the Learning Experiences of the Students:

Delivery is a hybrid of traditional distance education and online learning together with a number of face-to-face / on-line tutorials. In addition, there are online discussions moderated by a subject matter expert on elements of each module to reinforce the learning and maximise the benefit of the programme for participants.

Research Findings Incorporated in to the Syllabus (If Relevant):

Prime Texts:

AUA (2007) Module Study Notes , AUA
James P Womak & Daniel T Jones (2003) Lean Thinking , Free Press, London & New York
Taiichi Ohno (1988) Toyota Production System: Beyond Large-Scale Production , Productivity Press, Portland, Oregon
Mike Rother & John Shook (2003) Learning to See , The Lean Enterprise Institute, Brookline, Massachusetts
Richard L. MacInnes (2002) The Lean Enterprise Memory Jogger , Goal/QPC, Salem, NH,
James P. Womack & Daniel T. Jones () Lean Thinking, Banish Waste and Create Wealth in Your Corporation ,

Other Relevant Texts:

Programme(s) in which this Module is Offered:

Semester - Year to be First Offered:

Autumn - 08/09

Module Leader: