Manufacturing Strategies - University of Michigan
Manufacturing Strategies
MFG 426
Winter ‘06, Section 001
Updated May 30, 2005
Class Time: Tuesday and Thursday 6:00 – 8:00 p.m.
Class Location: Chrysler Center 165
Instructor: Bob Anderson
reander@engin.umich.edu
Office: 1783 IOE
Office Hours: T,Th 4:00 – 6:00 p.m.
Office: 734-647-8720
Home: 517-347-8974
GSI: Sarah K. Womack
womacks@umich.edu
Office: 2828 IOE
Office Hours: Fri 4:00 – 6:00 p.m & by appt.
Class Web Site:
Required Texts:
• Learning to See, J. Shook & M. Rother, Lean Enterprise Institute, 1998.
• Coursepack (online)
Suggested Text:
• A Study of the Toyota Production System, S. Shingo, Productivity Press.
Course Purpose
IOE 425 / MFG 426 introduces you to one of the most successful manufacturing strategies in operations: lean manufacturing, as seen at Toyota and other companies. Lean manufacturing is a philosophy which applies both on and off the factory floor. Lean manufacturing is NOT a set of tools to choose inconsistently.
Course Outcomes
• Understand the history and relevance of the transition from craft to mass to lean production
• Understand the basic flow of production (automotive examples)
• Understand the roots of both mass and lean production (Functional Concepts)
• Understand the concepts and elements of a lean manufacturing system (Toyota Production System Model)
• Understand and analyze production flow using Value Stream Mapping
• Learn to assess an operations throughput and quality capabilities
• Learn to identify improvement opportunities using lean tools.
• Learn to identify potential benefits through the application of lean tools
• Learn to offer valid recommendations for improvement using proper planning tools and format
• Experience working in a team setting to execute a lean analysis and improvement proposal
Policies and Procedures
Website… The homework, midterm, selected class slides, and other information will be located on MEOnline.
Homework… There will be nine homework assignments in the course. Homework is due on-line by 4:00 pm E.S.T. on the due date. We will drop your one worst homework grade before computing your final grade. We will not accept late homework.
Teams…Both the video and the plant reports are designed to be completed in teams of three to six people. It is to your advantage to form your team early. You do not have to have the same team for both reports. Each team is required to create a “Team Contract” and submit a copy to the instructor. We will not accept a report unless we have a Team Contract from that team. These team assignments are not part of the nine homework assignments. Off-campus students who must travel to different cities to meet as a team may be allowed to do individual projects to avoid the extra time and inconvenience of traveling.
Team Contract…The Team Contract is a memo of understanding between the team members. In the Team Contract, the team will
• list ground rules (e.g., do your meeting times imply “Michigan time”? What if you miss a meeting? How are you going to assign roles and work? What kind of preparation should each member have done before meetings?),
• hiring procedures (i.e., what if someone wants to join your group after the initial Team Contract is signed), and
• warning/firing procedures (e.g., how will you determine if a team member is not doing his/her share of the work? How will you warn them and what method will you use to record that warning? How many warnings do they get? If they fail to improve, then what? Do you meet with the instructor or GSI at a certain point?)
Video and Plant Reports…There will be two group reports, one based on a video tour of a plant and one from a video standardized work exercise. Reports are to be submitted by hard copy, with two copies submitted to facilitate grading. Reports are due to the site coordinator or mailed on the due date. Format for the team project reports will be outlined in detail in the assignment. Compliance to the format will be considered in the grading of the reports.
Late Video and Plant Reports…Late reports will not be accepted unless prior arrangements are made with the instructor.
Exams… There will be a midterm and a final exam. The exams will be based on any material assigned or discussed in class, as well as team projects. The final exam will be given in the last session of the class and is closed book and closed notes.
Missed Exams…If you miss an exam without either a certified medical excuse or prior instructor approval, you will receive a zero for the grade. Exams missed with a certified medical excuse or prior instructor approval will be dealt with individually.
Exam Re-Grades…If you wish to have a portion of your midterm or final exam reconsidered, you must submit the original exam (or print out of the question and answer if referring to the midterm) and a written explanation of why you deserve more points. Re-grade requests will not be accepted in the first 48 hours after the exam has been returned to you. You must submit a re-grade request within 9 days after the exam has been returned to you (7 days after the blackout period ends).
Calculation of Course Grade…A weighted average grade will be calculated as follows: Homework (8 at 1%) – 8%; Team Reports (2 at 20% each) – 40%; Midterm – 25%; Final – 27%. A weighted grade of 98 or above is guaranteed a course grade of A+, 90 or above at least an A-, 80 or above at least B-, 70 or above at least C-, and 60 or above at least D-.
Notice: Grades are not curved in this course. It is theoretically possible for everyone in the class to get an A (or an F). Your grade depends only on how you do, not on how everyone else in the class does.
Gray areas between letter grades…There will be a “gray area” of a fraction of a point around the specified numerical cutoff grades (except 98), within which a ± system will be used. Two people getting the same weighted average grade (say, 89.9) might therefore get different course grades (A- and B+). If you are in one of the gray areas, whether you get the higher or lower grade depends on your participation in class and exam scores compared to project scores (exams given higher importance.)
Consulting with the instructor and GSI…We strongly encourage you to discuss academic or personal questions with the course instructor or GSI during their office hours or by email.
Course Schedule
Note: All dates shown are for the off-campus class. On-campus students will
follow the same schedule only one week earlier.
January 12 – History and Introduction
At the end of this session, you should be able to:
• Define “lean” and “mass”
• Identify the differences in the characteristics of mass and lean
Read for January 17: Learning to See pages 3-34
Homework Due January 17: online quiz #1
January 17 – Defining and Mapping the Current State
At the end of this session, you should be able to:
• Draw a Current State Map
• Describe the current state of the average North American factory
• Explain why an organization would want to value stream map
Read for January 19: waste handout*, TPS* pages 22-24; Learning to See
pages 41-54
Homework Due January 19: online quiz #2
January 19 – Waste and Defining the Ideal & Future State
At the end of this session, you should be able to:
• Define the 7+1 categories of waste
• Identify characteristics of waste in an organization
• Explain the broad steps to eliminating waste
• Identify the waste, determine removal options, select one, and justify your answer for a given situation
• Identify characteristics of the ideal state
Read for January 24: problem solving handout*, 5’S’ handout*
Homework Due January 24: online quiz #3
January 24 – Problem Solving and 5S
At the end of this session, you should be able to:
• Explain and apply as least one method for finding the root cause of a problem
• Describe the synergies between lean and six sigma
• Define and apply the 5 “S’s”
Read for January 26: TPS* pages 12, 20-21; Identifying Fake Flow
Homework Due January 26: online quiz #4
January 26 – Getting There: Continuous Flow
At the end of this session, you should be able to:
• Define “one piece” or “continuous” flow
• Describe the benefits of continuous flow
• Explain the benefits of using cells
• Evaluate when to use a cell in a given line
Read for January 31: TPS* pages 13-19
Homework Due January 31: online quiz #5
January 31 – Just-In-Time Pull Systems
At the end of this session, you should be able to:
• Classify a “push” system and a “pull” system
• Evaluate when to pull and when to flow, select one for a given situation, and justify your choice
• Explain the concept of “kanban”
• Evaluate the types of kanban tools available, select one or create your own, and justify your choice
• Determine a starting number of kanbans with the “rule of thumb” equation
Read for February 2: Learn to See pages 57-99
Homework Due February 2: online quiz #6
February 2 – Mapping the Future State (Guest Speaker: Mike Rother)
At the end of this session, you should be able to:
• Draw a Future State Map and explain your choices
• Determine the starting size of a supermarket or FIFO line and explain your reasoning
• Determine the number of operators needed for a process and explain your reasoning
• Calculate takt and pitch
• Define the pacemaker process
• Select the pacemaker process and justify your choice
• Formulate a yearly value stream plan
• Explain how value stream mapping fits into the “big picture”
Midterm: February 3 – February 7 (due on-line before 5:00 p.m.EDT)
February 7 – Future State Mapping (Conclusion) & Tuttle Springs Video Tour
Tuttle Springs Team Report Due: February 14
Read for February 9: TPS* pages 32-34; Standard work handout
February 9 – Standard Work and Continuous Improvement
At the end of this session, you should be able to:
• Define standard work
• Explain the benefits of standard work
• Describe the role standard work plays in continuous improvement
• Complete a standard work sheet and combination table for static work, including apportioning the work
• Explain the role continuous improvement plays in the lean philosophy
Homework Due February 14: standard work exercise homework #7
February 14 – Standardized Work Video Team Exercise
Standardized Work Team Report Due: February 21
Read for February 16: TPS* pages 26-30, Jidoka handout*, TPM handout*
Homework Due February 16: online quiz #8
February 16 – Jidoka, Andon and TPM
At the end of this session, you should be able to:
• Define Jidoka and its parts
• Explain the benefits of Jidoka and its parts
• Evaluate potential Jidoka options, select one, and justify your choice
• Describe TPM and its benefits
Read for February 21: Supply Chain handout*, Leadership handout* TPS*,
page 7-10, 41, 43
Homework Due February 21: online quiz #9
February 21 – Supply Chain, Implementation
At the end of this session, you should be able to:
• Distinguish between “traditional” and “lean” supply chain management
• Explain the benefits of “lean” to the entire supply chain
• Describe the role of leaders in the lean organization and supply chain
• Explain the major barriers to implementation and how to overcome
them
February 23 – Review Session for the Final Exam, Course Evaluation
February 28 – Final Exam
The final exam will be closed book, closed notes. It will take place in the regular classroom during the regular class time.
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