Course Title / Code LEAN MANUFACTURING

Course Code
Course Type CORE
Course Nature HARD COURSE
L-T-P-O Structure 3-0-2-1
Objectives Design a globally competitive manufacturing organization by
developing the skills to implement lean manufacturing in industry
and manage the change process to achieve continuous improvement
of efficiency and productivity.
Learning Outcomes By studying this subject, the student will be able to:
identify and understand the key requirements and concepts in
lean manufacturing and to initiate a continuous improvement
change program in a manufacturing organisation
apply the tools in lean manufacturing to analyse a manufacturing
system and plan for its improvements
manage the manufacturing system to achieve six sigma quality
and sustainability.
Pre-requisites None
MANAV RACHNA UNIVERSITY
M.Tech. Program
Production & Manufacturing Engineering

Sections Weightage
A 25%
B 25%
Syllabus
C 25%
D 25%
TOTAL 100%

SECTION A
INTRODUCTION TO LEAN MANUFACTURING: Objectives of lean manufacturing,
Key Principles and Implications of Lean Manufacturing, Traditional Vs Lean Manufacturing.

LEAN MANUFACTURING CONCEPTS: Value creation and waste elimination, Main

kinds of waste, Pull Production, Different models of Pull Production, Continuous flow,
Continuous improvement (Kaizen), Worker involvement, Cellular layout, Administrative
lean.

SECTION B
LEAN MANUFACTURING TOOLS AND METHODOLOGIES: Standard work,
Communication of standard work to employees, Standard work and flexibility, Visual
controls, Quality at the source, 5S principles, Preventive maintenance, Total quality
management, Total productive maintenance, Changeover/setup time, Batch size reduction,
Production leveling.

VALUE STREAM MAPPING: The current state diagram, the future state map, Application
to the factory simulation scenario, Line Balancing, Poka-Yoke, Kanban, Overall equipment
effectiveness.

SECTION C
JUST IN TIME MANUFACTURING: Introduction, Elements of JIT, Uniform production
rate, Pull versus push method, Kanban system, Small lot size, Quick & Inexpensive set-up,
Continuous improvement, Optimized production technology.

ONE-PIECE FLOW: Process Razing Techniques, Cells for assembly line, Case studies.

SECTION D
IMPLEMENTING LEAN: Roadmap, Senior Management Involvement, Best practices.

RECONCILING LEAN WITH OTHER SYSTEMS: Toyota production system, Lean &
Six Sigma, Lean and ERP, Lean with ISO9001:2000.

LABORATORY
(Softwares Required: eVSM software, Pro-Planner, RFID, XFMEA software, Timer pro
Software, Minitab software)

1. Value Stream Mapping Creation of current state diagram using eVSM software
2. Value Stream Mapping Development of future state map for the above set up
3. Evaluation of cost benefit analysis of implementing lean system A case study
4. Layout design and study of layout performance
5. Development of a Poka-Yoke (fool proof) system for a process
6. Generation of a Production plan using Pro-Planner
7. Calculation of lead time and WIP using RFID
8. Design of automatic inspection line using Machine Vision System and Pneumatic
System
9. Calculating Risk Priority number using XFMEA software
10. Identification of VA, NVA, Standard time calculation and Line balancing using Timer
pro Software
11. Ergonomic risk assessment of assembly station using RULA method
12. Process capability evaluation using Minitab software

Text Books:
1. Lean Manufacturing by By Aza Badurdeen
2.
3. http://www.leanmanufacturingconcepts.com/
4. http://www.strategosinc.com/
5. http://www.scodanibbio.com/site/access/e_courses/downloads/preview/vsm_pw.pdf

References:
1. Askin R G and Goldberg J B, Design and Analysis of Lean Production Systems, John
Wiley and Sons Inc., 2003.
2. Michael L George, David T Rowlands, Bill Kastle, What is Lean Six Sigma, McGraw
Hill, New York, 2004.
3. Micheal Wader, Lean Tools: A Pocket Guide to Implementing Lean Practices,
Productivity and Quality Publishing Pvt Ltd, 2002.
4. Kenichi Sekine, One-Piece Flow, Productivity Press, Portland, Oregon, 1992.
5. Alan Robinson Continuous Improvement in Operations, Productivity Press, Portland,
Oregon, 1991.
6. Joseph A De Feo, William W Bearnard , Juran Institutes Six Sigma Break Through and
Beyond, Tata McGraw Hill Edition, New Delhi, 2004.
7. Richard B Chase F Robert Jacobs and Nicholas J Aquilano, Operations Management
for Competitive Advantage, McGraw Hill/Irwin; Tenth Edition, 2003.
8. Poke - Yoke, "Improving Product Quality by Preventing Defects", Productivity Press,
1992.