Birla Institute of Technology & Science, Pilani

Work Integrated Learning Programmes Division

Manufacturing Excellence
Digital Learning Handout

Course Title Manufacturing Excellence

Course No(s) ET ZC417
Credit Units 4
Credit Model 1+1+2
Instructor-In-Charge Dr. Naga Vamsi Krishna Jasti
Version Number Ver 1.2
Date 16th July 2016

Course Objectives:
 To enable you to design a globally competitive manufacturing organisation using manufacturing
excellence techniques.
 To develop the skills to implement manufacturing excellence principles in industry and manage the
change process to achieve continuous improvement of efficiency and productivity.
 To enhance knowledge of participant to develop an integrated approach to address dynamic
organizational problems

Text Book(s):
T1 Besterfield D. H., et al., "Total Quality Management", Pearson Education, 1999.
T2 Pascal Dennis, “Lean production simplified”, Second Edition, Productivity Press, 2007

Reference Book(s) & other resources:

R1 Voss C.A. "Manufacturing Strategy: Process and Content", Chapman & Hall, London, 1992.
R2 Nicholas J.M., "Competitive Manufacturing Management", Tata McGraw Hill Publishing Company
Limited, New Delhi, 2001.
R3 Mohanty R.P. and Deshmukh S.G., “Advanced Operations Management”, Pearson Education, 2003.
R4 Jasti, N.V.K and Sharma, A (2014) “Lean manufacturing implementation using value stream
mapping as a tool: A case study from auto components industry”, International Journal of Lean Six
Sigma Vol. 5 No. 1, pp. 89-116.

LEARNING OUTCOMES

LO1 Able to adapt the continuous improvement program to achieve excellence in manufacturing
functions.
LO2 Able to apply lean manufacturing and quality system tools to enhance the performance factors of
production line.

LO3 Able to conduct, analyze and interpret experiments on process models

LO4 Able to identify opportunity, study, analyze and suggest possible improvement on the production
line

LO5 Able to apply critical lean manufacturing tools to enhance the existing production line.

Experiential Learning Components:

1. Lab work: FlexSim
2. Project work: None.
3. Case study: None
4. Work integrated Learning Exercise: None.
5. Design work/Field work: None.

Content Structure:

Contact Hour List of Topic Title Sub-Topics Reference

 Manufacturing Excellence: Class Notes
Importance, Overview,
Introduction
Characteristics, Priorities &
1-2 Manufacturing
Framework.
Excellence
 Case Study to show importance of
manufacturing excellence
 Manufacturing Strategy & Types Class Notes
 Introduction to Operations strategy
 Competitive priorities
 Incorporating manufacturing
3-4 Manufacturing Strategy
perspective in corporate Strategy,
 Missing the links in manufacturing
strategy
 Assignment
 Lean Manufacturing, Traditional T2
Manufacturing & JIT
Introduction to Lean  Evaluation of production systems
5-6
Manufacturing  Types of wastes
 System and System thinking
 Quiz
 Stability & Standardize work T2
Stability and
7-8  Five pillars of lean manufacturing
Standardized work
 Exercise
 Standard Chart T2
9-10 Standardized work
 Production capacity chart
  Standardized work combination
table
 Standardized work analysis chart
 Job element sheets
 Overall efficiency and individual
efficiency
 Common Layouts.
 Exercise
 JIT & Its Principles T2
11-12 Just in Time Production
 Exercise
Just in Time  Value stream mapping T2
13-14 Production—Value  Exercise
Steam Mapping
 Jidoka T2
15-16 Jidoka
 Exercise
 Review: complete syllabus
17-18 Review
 FlexSim Assignments
 Understanding quality T1
Introduction to Total  Difference between quality control
Quality Management and TQM
19-20
(TQM)  Requirements, Role & Elements of
TQM
 Assignment
 Qualitative and Quantitative T1
tools in TQM
21-22 Benchmarking
 Benchmarking
 Case Study: Benchmarking
 Failure Mode Effective Analysis T1
Failure Mode Effective
23-24
Analysis
(FMEA)
 Case Study: FMEA
Quality Functional  Quality Functional Deployment T1
25-26 Deployment (QFD)
 Case Study: QFD
 Management Tool T1
 Why, Why analysis
 Force Field Analysis
 Nominal Group Technique
 Affinity diagram
 Interrelationship Digraph (ID)
Management Tools in
27-28  Tree diagram
TQM
 Matrix diagram
 Prioritization Matrices
 Process Decision Program Chart
(PDPC)
 Activity network diagram
 Assignment
 Total Productive  Maintenance & TPM T1
29-30 Maintenance  Exercise

 Review: complete syllabus Class Notes

31-32 Review
 FlexSim Assignments

Evaluation Scheme:

Legend: EC = Evaluation Component; AN = After Noon Session; FN = Fore Noon Session

Evaluation Name Type (Open Weight Duration Day, Date, Session,
Component (Quiz, Lab, Project, Mid- book, Closed Time
term exam, End semester book,
exam, etc.) Online, etc.)
Quiz-1 &2 Online 10% August 23 – September
EC - 1 01, 2019
Virtual Lab Online 20% To be announced
Mid-Semester Test Closed Book 30% 2 hours Friday, 20/09/2019
EC - 2 (FN)
10 AM – 12 Noon
Comprehensive Exam Open Book 40% 3 hours Friday, 15/11/2019
EC - 3 (FN)
9 AM – 12 Noon

Syllabus for Mid-Semester Test (Closed Book): Topics in Contact Hours: 1 to 16

Syllabus for Comprehensive Exam (Open Book): All topics
Important links and information:
Elearn portal: https://elearn.bits-pilani.ac.in
Students are expected to visit the Elearn portal on a regular basis and stay up to date with the latest
announcements and deadlines.
Contact sessions: Students should attend the online lectures as per the schedule provided on the Elearn
portal.
Evaluation Guidelines:
1. EC-1 consists of either two Assignments or three Quizzes. Students will attempt them through the
course pages on the Elearn portal. Announcements will be made on the portal, in a timely
manner.
2. For Closed Book tests: No books or reference material of any kind will be permitted.
3. For Open Book exams: Use of books and any printed / written reference material (filed or bound)
is permitted. However, loose sheets of paper will not be allowed. Use of calculators is permitted
in all exams. Laptops/Mobiles of any kind are not allowed. Exchange of any material is not
allowed.
4. If a student is unable to appear for the Regular Test/Exam due to genuine exigencies, the student
should follow the procedure to apply for the Make-Up Test/Exam which will be made available
on the Elearn portal. The Make-Up Test/Exam will be conducted only at selected exam centres on
the dates to be announced later.
It shall be the responsibility of the individual student to be regular in maintaining the self-study schedule
as given in the course handout, attend the online lectures, and take all the prescribed evaluation
components such as Assignment/Quiz, Mid-Semester Test and Comprehensive Exam according to the
evaluation scheme provided in the handout.
 Manufacturing Excellence: Simulation Lab

Course Handout

Contents:

1. Scope of Lab
Objective of Lab
2. List of Simulation Experiments
Software Tool Used: FlexSim
3. Learning Outcomes of Lab
4. Instruction Schedule
5. Evaluation Scheme
 Faculty Name Yogesh Danekar
& Contact 8380078189 (Contact through What’s App messages only)
Details

Scope of the lab:

 Manufacturing Excellence simulation lab enables the students to understand and implement various
manufacturing system practices to enhance the organization performance.

Objectives of Lab:
 To simulate and analyse various manufacturing environments to solve pertinent problems.

Learning Outcome of the lab

 Able to model and simulate manufacturing production systems
 Able to analyse a given system and suggest improvements.
 Able to convert existing production system to pull production system.
 Able to model, analyse and identify various types of wastes using value stream mapping.

List of simulation experiments

Tut. No. Practice Tutorial Description

To simulate and find out the performance

1 Work Force management
2 Lead time Estimation
3 conditions and identify the various
U shaped Layout Vs Line Layout
4 Pull Production Vs Push Production
5 resources need to be modelled and
Line Balancing
6 Batch production Vs Continuous
production
and utilization of various elements in the
production line
For conventional production line multiple
resources need to be modelled and
analysed in a particular given layout.
Estimate Lead time of particular
production line
To Simulate U shaped layout for given
advantages of U shaped layouts over Line
layout
Push production scenario will be given for
modelling and analysis and based on the
findings Pull production system need to be
developed, modelled and finally need to
analyse in various operating conditions.
For conventional production line multiple
analysed in a particular given layout. Line
balancing has to perform on given layout.
Model and analyse batch production
layout and continuous layout for a given
product and suggest the optimal system.
 7 Kanban Simulate the process of Kanban System
8 Simulate the preventive maintenance
Preventive Maintenance
system

Instruction Schedule
Lab Class work Instructions Online 11.08.2019 :Lab Session 1 2 Hrs
Delivery 18.08.2019 :Lab Session 2
25.08.2019 :Lab Session 3
08.09.2019 :Lab Session 4
13.10.2019 :Review Session

Evaluation Scheme
Evaluation Name Type Marks Dates Lab Exam Date Duration
Component

Quiz based Online 08

on virtual lab

Assignment Online 12 Phase I duration Regular 7 Days

EC - I based on 12.08.2019 - 31.10.2019- 07.11.2019
virtual lab 10.09.2019
Phase II duration Makeup 7 Days
12.10.2019 - 08.11.2019-15.11.2019
27.10.2019

Note: After completion of every practice tutorial problem, take a snapshot and include the same in the
final assignment PPT lastly. Quiz questions will be based on the practice tutorial problems and results.

Instructor-in-charge

(ET ZC417)