Credits 3

Pre-requisites - None

Core/Elective - Technical Elective Course

To introduce the main Lean Manufacturing concepts and to cultivate lean thinking in the mindset of manufacturing engineers in order for them to use these concepts in their day to day decision making.

At the end of this course, students should be able to:

1. Explain the significance of Lean concepts for manufacturing.

2. Use Lean techniques for improving the performance of manufacturing industries.

3. Identify the challenges and future directions of Lean Manufacturing.

1. Introduction to Lean Manufacturing: History of Lean manufacturing, Evolution of Lean manufacturing concept, House of Lean manufacturing, Building blocks of Toyota Production System Seven types of wastes, Difference between traditional and lean firm Value, Stream Mapping

2. Foundations of Lean Thinking: Toyota-way philosophy, Visual management, Stable and standardized processes, Level production

3. Lean Manufacturing Techniques: Production smoothing concepts Just in Time Production (JIT), Kanban systems Single piece flow concept, Single Minute Exchange of Dies (SMED) Process visualization

4. Quality Conscious Manufacturing: In-station quality Autonomous defect control, Total Quality Management (TQM) concept, Continuous process improvement, Lean 6 Sigma concept

5. Total Productive Maintenance: Basic steps of TPM Pillars of TPM, Different indices of TPM

6. Human Factor in Lean Manufacturing: Lean leadership Sustainability, Cultural and sociological aspects of Lean implementation

7. Extensions of Lean Manufacturing and Future Challenges: Agile manufacturing Smart manufacturing