To introduce the main elements of the Lean process improvement framework, focusing on quantity control and human engagement, through lectures, readings and laboratory experience. To prepare students to engage in performance improvement projects during Coop.

Introduction to lean and continuous improvement philosophy in context of quantity control and its relationship with quality control and broad business processes such as new product development and supply-chain. Forms of waste and PDSA. Supply-chain context, supply chain reference model SCOR and performance criteria. Problem identification and 5S, as initiation for structured problem analysis and enquiry. Process mapping, focusing, critical questioning, and process improvement. Work standardisation, allowances, rating, and standard work. Work-flow, types of layout, consequences: material movement, Littles law, flow factor. Systematic Layout Planning, layout design and improvement. Inventory control, classical economic order quantity, safety stocks, batch size and consequences: Little's law, flow factor and variability effects. Push planning (MRP/CRP/MRPII). Setup time, setup time reduction programmes, SMED, flow factor, flexibility and commercial significance. Pull material flow systems eg kanban, drum-buffer-rope. Production line balancing and production flow smoothing, goal-chasing methods, and significance. Engagement of people, kaizen and process improvement teams, organisational conditions eg structure, culture and reward systems. Lean thinking, policy deployment and organisational cohesion.

On successful completion of this module, students should be able to: Define key concepts such as PDSA, continuous improvement, kanban, kaizen, SMED. Discuss problem-controlled solution cycle framework. Discuss lean and continuous improvement philosophy in context of quantity control and its relationship with quality control and broad business processes such as new product development and supply-chain. Discuss forms of waste. Discuss PDSA in context pf supply-chain operations structure process and outcomes. Discuss problem identification and 5S, as initiation for structured problem analysis and enquiry. Apply and discuss process mapping, focusing, critical questioning, and process improvement. Apply and discuss work standardisation, allowances, rating, and standard work. Work-flow, types of layout, consequences: material movement, Littles law, flow factor, Systematic Layout Planning, layout design and improvement. Apply and discuss inventory control, classical economic order quantity, safety stocks, batch size and consequences (Little's law, flow factor and variability effects), push planning (MRP/CRP/MRPII). Describe and discuss setup time, setup time reduction programmes, SMED, flow factor, flexibility and commercial significance. Describe and discuss pull material flow systems eg kanban, drum-buffer-rope, and their significance. Apply and discuss production line balancing and production flow smoothing, goal-chasing methods, and significance. Describe and discuss issue relating to engagement of people, kaizen and process improvement teams, organisational conditions eg structure, culture and reward systems. Describe and discuss the main elements of lean thinking, policy deployment and organisational cohesion.

On successful completion of this module, students should be able to: Respond to apparently technical problems with humanised values. Appreciate the duality of time as resource and as delay on response.

N/A

Lectures, reading and hands-on lab experience and report-writing.