MN 102 - Lean Manufacturing Principles
Description
The course focuses on the study and practice of core competencies which create a culture for corporations to eliminate waste activities. This course includes the following concepts of Lean Manufacturing practices: Value Stream Mapping, Waste Identification, Kaizan, SMED, Kan Ban, Problem Solving, 5S, Standardized Work, and Poke Yoke. Students are involved in practical application, project presentation and project management.
Credit Hours: 2
Contact Hours: 2
School: School of Business & Industry
Department: Manufacturing
Discipline: MN
Major Course Revisions: N/A
Last Revision Date Effective: 20230217T13:59:10
Course Review & Revision Year: 2027-2028
Course Type:
Program Requirement- Offering designed to meet the learning needs of students in a specific GRCC program.
Course Format:
Lecture - 1:1
General Education Requirement: None
General Education Learner Outcomes (GELO):
NA
Course Learning Outcomes:
1. Demonstrate techniques to successfully complete a Kazian event.
2. Develop a current state value stream map.
3. Develop a future state map with sunburst associated by cost of waste and lean objectives.
4. Demonstrate, define and utilize team concepts.
5. Lead a waste walk, determining the values associated with cost of waste.
6. Develop strategies to provide standardization and sustaining efforts in a 5’s, while producing a safe environment for employees.
7. Consider the context, costs, benefits and consequences of potential solutions to problems or issues.
8. Adapt to change by developing new ideas or finding improved ways of doing things.
Approved for Online Delivery?: No
Course Outline:
I. Introduction to Lean Principles
A. What is Lean
B. Shifting the paradigm
C. Background of Lean (Ford & Toyota)
D. Continuous Improvement model
II. Value Stream Mapping
A. Overview of VSM
B. Symbols and Icon
C. Current State of operation
D. Mapping in paper & pencil
E. Current state burst-opportunities for improvements
F. Future State what is possible
G. Understanding the numbers
III. 8-Deadly Waste
A. Determine how we see waste
B. Categorization of waste
C. Waste Walk in factory-conduction
D. Impact of waste
E. Lean tool selection for waste elimination
IV. 5s (added 1’s-Safety)
A. Overview the 6’s program
B. Determine management participation
C. Provide opportunity to complete simple 3’s
D. Standardize and Sustain Actives in real world application
E. Corporate Importance of 6’s
F. Value of seeing waste from 6’s implementation
V. Standardized Work
A. Develop knowledge in process management
B. Write Standard work procedures
C. Apply visual management systems with written format
D. Training on work station applications in manufacturing
E. Value of employee inputs on standard development
VI. SMED Single Minute Exchange of Dies
A. Overview of SMED (quick change systems)
B. Techniques to study time (current condition)
C. Video Process of Change
D. Evaluation tools
E. Benefits to both (workforce and corporation)
F. Reductions of inventory levels to improve KAN BAN
VII. KAN BAN
A. One piece flow and Kan Ban
B. Continuous Flow
C. FIFO
D. 5 elements to a good Kan Ban
E. Signal Devices in Kan Ban
F. Kan Ban cycles
G. Variables to over come
VIII. Problem Solving and Poke Yoke
A. Techniques for Problem Solving
B. Techniques to error proof
C. Prevention verse detection
D. Employee buy in
IX. Kaizan
A. Process of continuous improvement
B. How to implement a successful event
C. How to gain employee confidence and buy in
D. Pitfall to avoid
Mandatory CLO Competency Assessment Measures:
None
Name of Industry Recognize Credentials: None
Instructional Strategies:
Lecture: 20-30%
Hands-on activities: 50-70%
In classroom demo’s: 20-30%
Mandatory Course Components:
1. Value stream mapping current state pen and pencil
2. Future State Value stream mapping with start burst
3. 5’s activity
4. SMED video and SMED activity
Academic Program Prerequisite: None
Prerequisites/Other Requirements: None
English Prerequisite(s): None
Math Prerequisite(s): None
Course Corerequisite(s): None
Course-Specific Placement Test: None
Course Aligned with IRW: N/A
Consent to Enroll in Course: No Department Consent Required
Total Lecture Hours Per Week: 2
Faculty Credential Requirements:
Master’s Degree (GRCC general requirement), Professionally qualified through work experience in field (Perkins Act or Other) (list below)
Faculty Credential Requirement Details: Standard qualifications for the School of Workforce Development apply with a minimum of 4000 work-hours in a related field. Qualifications can include a Bachelor’s of Science in Manufacturing, Engineering, Automotive or related field. The instructor needs to be diverse in the study of Lean concepts and practical team applications.
General Room Request: ATC 2nd floor, lab room 242
Maximum Course Enrollment: 20
Equivalent Courses: None
Dual Enrollment Allowed?: Yes
Number of Times Course can be taken for credit: 1
Programs Where This Courses is a Requirement:
Plastics-Polymer Engineering Technology, A.A.A.S.
People Soft Course ID Number: 104326
Course CIP Code: 48.9999
High School Articulation Agreements exist?: No
If yes, with which high schools?: NA
Non-Credit GRCC Agreement exist?: No
If yes, with which Departments?: NA
Corporate Articulation Agreement exist?: No
If yes, with which Companies?: NA
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