shannon syllabus

8/6/2019 Shannon Syllabus

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Opermgt 408Lean Manufacturing Systems

Fall Semester, 2005http://blackboard.boisestate.edu

Dr. Patrick ShannonOffice:B213 F

Phone: 426-3786 Office (Shannon)

343-4358 Home (Shannon)e-mail: [email protected]

Hours:

Tuesday-Thursday 8:30 10:30

Tuesday 3:00-5:00

and by appointment

Course Objectives:

This course provides an overview of "Lean Manufacturing Systems as anapproach companies use to achieve world-class performance and customersatisfaction. This course will show how Lean Manufacturing principles and

techniques improve an organizations ability to provide added customer value onproducts. The concepts introduced in this course will build on the techniques and

tools introduced in Opermgt345. The focus of the course will be on introducing

these key concepts and tools by demonstrating how they are applied in decision-making situations.

Text:

Required:Lean Thinking, By James P. Womack and Daniel T. Jones, Simon andSchuster, 1996.The Goal, By Eli Goldratt and Jeff Cox, 1992, North River Press

(acquire from Library, local book stores, on-line, or borrow)

RecommendedThe Toyota Way, by Jeffrey Liker, McGraw-Hill, 2004

Prerequisites:Opermgt 345 or permission of the instructor


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Software:We will make use of Microsoft EXCEL and ProModel,. ProModel is

available on the College of Business network in the student lab. You can alsopurchase a Student Version at http://www.Promodel.com

Course OutlineWeek of TopicAugust 23 Course Introduction

Reading Assignment {Chapter 1-5}

August 30 Value-Adding Management and Time-Based Competition

Value Stream Mapping

September 6 New Paradigms The HP Push/Pull VideoPush

Pull

September 13 Value Stream Mapping Work 9/13/05 No ClassValue-Steam Project Presentations Projects Due 9/15/05

September 20 Throughput - WIP Cycle TimeLine Balancing and VariabilityLean Assembly

September 27 Theory of Constraints

Reading Assignment {The Goal}

TOC Case Assignment-Lab Work Using Pro-Model

October 4 TOC Project Work 10/4/05TOC Case Due 10/6/05

October 11 Implementing LeanReading Assignment {Chapters 6-11}

October 18 Total Productive Maintenance (TPM)

The 5 SsLEAN Application Exercise Round 1 10/20/05

October 25 Reducing Change-Over Times

November 1 Lean Application Team Meetings No Class 11/1/05LEAN Application Exercise Round 2 11/3/05


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November 8 Increasing Yield Welco ExamplesLEAN Application Exercise Round 3 11/10/05

November 15 Visual Management and Error Proofing

LEAN Application Exercise Round 4 11/17/05

November 22 Thanksgiving

November 29 Lean Manufacturing MetricsLEAN Application Exercise Round 5 12/01/05

December 6 Term Project Presentations 12/6/05 and 12/08/05

Project Papers Due 12/08/05

December 13 Final Exam 12/13/05 10:30 12:30 PM******LEAN Application Exercise Report Due 12/13/05

Assignments and Projects:

Value Stream Mapping Assignment (50 points)For your company or for one in which you can gain access, you are to

develop a value steam map. Identify the value-adding and non-value-addingsteps. Provide one or more recommendations for how the organization canreduce the time spent on a non-value-adding step or how a non-value adding stepcan be eliminated. Prepare a one page report along with your value stream map.

Due: 9/15/05

Theory of Constraints Case Project (100 points)The objective of the TOC case is to make changes to a simulated

manufacturing process for the purposes of reducing the cycle-time and increasingthroughput. This will done using a commercial simulation package called Pro-Model which is available in the computer lab.

Due: October 6, 2005


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LEAN Application Exercise (200 points)

As part of a work team of 5-6 people, you will take on the role of anemployee at a computer mail order business. Each member of the team willassigned specific responsibilities for determining:

The correct total price for the order The correct date on which the order will

reach the customer.

The exercise will consist of five rounds. Each round will consist ofeight orders that will arrive in one minute intervals. The first round will bethe baseline run. The team must follow the assigned process with nochanges. In subsequent rounds, the teams will implement lean type process

improvements. The objectives are:

100 percent correct prices and deliverydates

minimum average order processing time

After five rounds, the team will submit a double spaced, writtenreport using the following format:

1. Round by Round discussion of the teams process

improvement Steps2. Improvement trends on key measures

3. Analysis of the teams overall approach andperformance4. A discussion of the extent to which the lessons from this

exercise could be applied to real business processes at theteam members organizations.

This exercise is valued at 200 points with 100 points allocated to teamperformance against the objectives and 100 points assigned to the final

report.

Due: 12/13/05

Term Project (200 points)

Teams of 2-3 students will work together on a term project in whichyou will apply one or more of the lean manufacturing tools introduced in

this course to a real business process in your company or anotherorganization. You final report should chronicle your efforts during thesemester including all major steps and the results achieved. During the weekof December 6th, each team will make a 15 minute professional presentationof their project. A written report, containing a full description of the leanmanufacturing project is due on December 8, 2005.

Final Exam (100 points)


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There will be only one exam a comprehensive final exam on December 13 th

at 10:30 AM

Educational Opportunities:

Final Exam 100 pointsValue-Steam Mapping 50 pointsLEAN Application Exercise 200 pointsTheory of Constraint Case 100 pointsTerm Project 200 points

Total 650 points

Grading Policy:90-100% = A

80-89.9% = B70-79.9% = C 60-69.9% = DBelow 60% = F

STUDENT CODE OF CONDUCT

Refer to Boise States Student Code of Conduct for definitions of cheating, plagiarism,and others forms of academic dishonesty as well as policies and procedures for handlingsuch cases. The Student Code of Conduct is found athttp://www2.boisestate.edu/student conduct

It is strongly encouraged that you familiarize yourself with this policy, as it isapplicable to all of your classes and dealings with the University.

Academic honesty is a core belief of the University. Any student foundplagiarizing, cheating or fabricating any assignment will receive an automatic F for thecourse and be dismissed from class immediately. No ifs, ands or buts about it!

Key Dates To Remember:September 2, 2005 Last day to Add this classSeptember 2, 2005 Last day to Drop without W

October 3, 2005 Last Day to Drop

Hints for Success In This Course:

Attend Class and be involved

Be Prepared ahead of classJoin a study group

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