Unit 1 Lean Manufacturing

10 lecture hours

• Evolution of lean
• traditional versus lean manufacturing
• ford production system concept of lean
• Toyota’s foray in lean
• Customer Need
• Lean tools: Process mapping value stream management- 3M
• 7 types of Muda
• 7 major losses reduction. cell layout
• line balancing
• Concept of kaizen
• steps involved in kaizen deployment
• Kanban concepts
• types of Kanban
• and practical application
• push vs pull
• changeover time reduction - single minute exchange of die
• concept of TPM
• maintenance - preventive
• time based and condition based
• autonomous maintenance, JIT, Autonomation
• Lean metrics: Identify lean metrics
• kaizen cloud identification in VSM
• lean assessment. improving targets and benchmarks

Unit 2 Six Sigma

6 lecture hours

• Historical Overview – Definition of quality – What is six sigma -TQM and Six sigma - lean manufacturing and six sigma- six sigma and process tolerance – Six sigma and cultural changes – six sigma capability – six sigma need assessments - implications of quality levels
• Cost of Poor Quality (COPQ)
• Cost of Doing Nothing – assessment questions

Unit 3 The Scope of Tools and Techniques

• Tools for definition – IPO diagram
• SIPOC diagram
• Flow diagram
• CTQ Tree
• Project 08 Subject Code: 3171515 w.e.f