Lean Manufacturing (ME 410)

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Principles of lean manufacturing are introduced that provide a systematic process for identifying and eliminating non-value activities (waste) in production processes. Students learn these principles through a series of mini-projects in the mechanical engineering shop, an all-day factory simulation workshop, and tours to local industry.

WEEK 1

Date Lecture (12-1pm) Laboratory (8:30-11:30am or 1:30-4:30pm) Homework (completed in course logbook)

Mon 5/15

1) Course Goals and Syllabus

2) Role of Engineering Logbooks

3) Lecture Topics (Slides / Notes)

Prior to Lab:

1) Complete:

2) Review:

3) Acquire a logbook and review the following:

During Lab:

1) Formulate Block Project groups

2) Shop Safety and Orientation Training

3) Block Project Introduction

4) Geometric Dimensioning and Tolerancing (GD&T)

5) Machine Plan Templates

COURSEWORK

1) Include at least one photo and annotation in your logbook each day that describes something interesting you did or learned in the shop.

2) Read All I Need to Know about Manufacturing I Learned In Joe's Garage, which is available to read in the Senior Design Suite or via etext (Amazon / iTunes).

3) Select four terms from the Lean Building Blocks Diagram that are well-illustrated in Joe's Garage. Define and explain each of these terms using examples from Joe's Garage.

4) Find information on the items listed below in the Machine Shop section of the Mindworks website and summarize in your logbook.

  • lathe parts/operation
  • mill parts/operation
  • edge finder
  • endmills
  • taps/dies
  • boring bar
  • chamfer/deburring tools
  • fits/tolerances
  • machining plans

5) Review the Block Project part drawings and outline a process how you might fabricate each part, referring to the items listed above where appropriate.

Tue 5/16

1) Discussion of Joe’s Garage

2) Lecture Topics (Slides / Notes / Terminology)

  • House of Lean Terms
  • Types of Waste
  • Introduction to 5S

1) Finalize Block Project Teams and begin project:

  • Group A: Mill Project
  • Group B: Lathe Project

COURSEWORK

1) Identify four concepts from the glossary of Joe’s Garage that are illustrated in the shop or design suite. Explain each concept and give a detailed description how each concept is implemented.

BLOCK PROJECT

1) Create manufacturing plan for mill and lathe portions of block project (to be continuously updated during the project).

KAIZEN PROJECT

1) Prepare for Kaizen Project Work:

Wed 5/17

1) Lecture Topics (Slides / Notes)

  • Lean Methodology
  • Lean Building Blocks
  • Kaizen Methodology
  • The 5 Whys
  • Fishbone Diagrams
  • Spaghettis Diagrams

2) Kaizen Project Selection

Block Project Work

  • Group A: Mill Project
  • Group B: Lathe Project


BLOCK PROJECT

1) Update manufacturing plans

2) Review Block Project Expectations

KAIZEN PROJECT

1) Current State Analysis

  • Identify existing resources
  • Determine best practices

2) Future State Development

  • Define value-added goals
  • Identify reasonable scope of work for given time-frame

3) Stakeholder Involvement

  • Meet with mentors and stakeholders

4) Review the Kaizen Project Feedback Form and Wikipage Info

Thu 5/18

1) Lecture Topics (Slides / Notes)

  • Value Stream Mapping
  • Present State Map
  • Process Improvement Strategies
  • Takt Time
  • Future State Map

2) Preparation for Factory Simulation Workshop

Block Project Work

  • Group A: Mill Project
  • Group B: Lathe Project

COURSEWORK

1) Create and analyze Present State map for the boat factory. Include as much process information as possible. Identify at least two lean concepts that could be implemented in a future state.

BLOCK PROJECT

1) Review Block Project Expectations as preparation for Block Project report

2) Generate manufacturing plan for 2nd half of the Block Project

KAIZEN PROJECT

1) Continue Current State Analysis and Future State Development

2) Order materials if needed

Fri 5/19

FACTORY SIMULATION WORKSHOP

1) Meet in GJ 112

  • AM Lab 8:30-11:30
  • PM Lab 1:00-4:00

2) Workshop Resources:

COURSEWORK

1) Construct a Future State Map based on the final iteration of the Factory Simulation Workshop.

2) Discuss discoveries/lessons learned from the Factory Simulation Workshop.

3) Analyze statistics from the Factory Simulation Workshop:

BLOCK PROJECT

1) Review Block Project Expectations as preparation for Block Project report

2) Generate manufacturing plan for 2nd half of the Block Project

KAIZEN PROJECT

1) Continue Current State Analysis and Future State Development

2) Order materials if needed


WEEK 2

Date Lecture Laboratory Homework
Mon

5/22

1) Workshop Debrief

2) Lecture Topics:

3) Planning for Logbook Review and Kaizen Project Review

1) Exchange block parts with complementary team (i.e. mill team exchanges with lathe team) but DO NOT PUT YOUR ASSEMBLIES TOGETHER. Complete the Block Project GD&T & Inspection Exercise

2) Complete True Position Worksheet 2

Block Project Work

  • Group A: Lathe Project
  • Group B: Mill Project

COURSEWORK

1) Read All that Matters about Quality I Learned In Joe's Garage, which is available to read in the Senior Design Suite or via etext (Amazon / iTunes).

2) Complete a Logbook Review Form (all portions) and tape it into your logbook. Bring your logbook to class.

BLOCK PROJECT

1) Document and discuss findings from block exchange. Consider the following in your discussion:

  • 3 Strengths (Why)
  • 3 Improvements (How)
  • 3 Insights/Lessons Learned (so What)

2) Update manufacturing plans as needed.

3) Review Block Project Expectations and Block Project Feedback Form as preparation for Block Project report

KAIZEN PROJECT

1) Kaizen Project Work

2) Prepare display materials for Kaizen Mid-Project Review, including:

  • copies of logbook notes
  • relevant CAD drawings, illustrations, & machine plans
  • reference material
  • completed Kaizen Project Review Form
Tue

5/23

1) Logbook review activity (form)

2) Kaizen Mid-Project Review

3) Planning for tours

Block Project Work

  • Group A: Lathe Project
  • Group B: Mill Project

COURSEWORK

1) Read pages 1-64 from All that Matters About Quality I Learned in Joe's Garage. In your logbook, answer the first batch of reflection questions.

BLOCK PROJECT

1) Prepare Block Project report for submission tomorrow (Wednesday) by 6pm. Review Block Project Expectations.

KAIZEN PROJECT

1) Document and discuss feedback received during Kaizen mid-project review.

2) Continue Kaizen Project work.

Wed

5/24

1) Lecture Topics:

2) Final Project Selection ( Final Project Documents)

3) Planning for tours

4) Discussion of All That Matters About Quality (Batch 1)

Group A: Lathe Project

Group B: Mill Project

COURSEWORK

1) Complete reading All that Matters About Quality I Learned in Joe's Garage. In your logbook, answer the second batch of reflection questions.

2) Review the Tour Scavenger Hunt assignment in preparation for industry tours.

BLOCK PROJECT

1) Block Project Write-Up due by 6pm. Place on wooden table in the design suite along with your hardware.

KAIZEN PROJECT

1) Document and discuss feedback received during Kaizen mid-project review.

2) Continue Kaizen Project work.

FINAL PROJECT

1) Begin Current State analysis

  • Identify existing resources
  • Determine best practices

2) Begin Future State development

  • define value-added goals
  • identify reasonable scope of work for given time-frame

3) Initiate Stakeholder Involvement

  • Meet with mentors and stakeholders
Thu

5/25

Industry Tours:

  • closed toed/heeled shoes
  • no sandals/heels/boots
  • long hair tied back
  • long pants, no shorts
  • safety equip. provided
  • ask permission for pictures
  • electronics off

Tour Schedule:

  • gather time: 7:15
  • location: red lot 64B
  • depart time: 7:30 am

Advanced Input Systems

  • Tour 9:30 to 12 AM

Bayshore Systems

  • 1:30 to 3:30 PM
  • return to UI at ~5:30 PM

COURSEWORK

1) Complete Tour Scavenger Hunt.

2) Formulate any outstanding questions that you would like to explore in tomorrow's debrief of the plant tours.

KAIZEN PROJECT

1) Continue Kaizen Project work.

FINAL PROJECT

1) Review Final Project Feedback Form in preparation for final project work.

2) Continue Current State analysis

3) Continue Future State development

4) Continue Stakeholder Involvement

Fri

5/26

1) Lecture Topics:

2) Discussion of All That Matters About Quality (Batch 2)

Kaizen Project Work

Final Project Work

KAIZEN and FINAL PROJECT WORK

1) Future State Refinement

2) Stakeholder Involvement

  • Gather feedback
  • Implement changes

3) Order materials for Final Project (if necessary).


WEEK 3

Date Lecture Laboratory Homework

MON 5/29 MEMORIAL DAY - NO CLASS

Tue

5/30

1) Review for exam

  • Takt Time
  • Internal/External Setup
  • Line Balancing
  • Poka-Yoke
  • Chaku Chaku
  • Heijunka Boards

2) Exam Prep Resources:

  • Lecture Slides
  • Lecture Notes
  • Distributed Texts
  • Plant Tour Notes
  • Factory Simulation Notes

Kaizen Project Work

Final Project Work

HOMEWORK

1) Complete the GD&T practice problems.

2) Use your logbook to synthesize your understanding of lean manufacturing concepts in preparation for the in-class exam:

  • House of Lean
  • Types of Waste
  • Plant Layouts
  • 5S Systems
  • Visual Controls
  • Kaizen Events
  • Value Stream Maps
  • Just-in-Time
  • Quality at the Source
  • Work Cell Design
  • Set-Up Reduction
  • Product Families
Wed

5/31

In-Class Exam

Kaizen Project Work

Final Project Work

KAIZEN and FINAL PROJECT WORK

1) Begin preparation of material for Snapshot, including:

  • Current State Analysis
  • Future State Development
  • Stakeholder Involvement
  • Solution Implementation
  • Realization and Deliverables
  • Project and Team Assessment
Thu

6/1

1) Exam Recap

2) Course Deliverables

3) Course Assessment

4) Snapshot Preparation

Kaizen Project Work

Final Project Work

HOMEWORK

1) Record insights from exam recap.

2) Complete a summative Logbook Review Form looking back across the entire course.

KAIZEN and FINAL PROJECT WORK

1) Finalize projects and prepare material for Snapshot:

  • Attach display material to foam core board.
  • Include CAD renderings, pictures, and other visualizations.
  • Include manufacturing plans and hardware artifacts when appropriate.
  • Prior to Snapshot, review your display with a mentors and other teams.
Fri

6/2

Lean Manufacturing Snapshot (12-1 pm)


Final Work in Shop

Shop and Design Suite Clean-Up

Compilation of Course Deliverables by 5pm

HOMEWORK

1) Place logbook in milk crate in Senior Design Suite by 5pm.

KAIZEN and FINAL PROJECTS

1) Project wrap-up activities:

  • Leave display out after Snapshot Event
  • Wiki pages must be approved by the Wiki mentors; address issues on your discussion page
  • Artifacts and drawing packages should be logged with Bill Magnie
  • Files should be logged with Steve Beyerlein