Module Details

Module Code: STAT6008
Title: Lean Manufacturing
Long Title: Lean Manufacturing
NFQ Level: Fundamental
Valid From: Semester 2 - 2016/17 ( January 2017 )
Duration: 1 Semester
Credits: 5
Field of Study: 5240 - Chemical & Process Eng
Module Delivered in: 1 programme(s)
Module Description: This module provides an introduction to methods, concepts, and theories associated with lean
manufacturing, including topics such as Total Quality Management (TQM) and Six Sigma.
Techniques such as Just in Time and Kanban, are explained. Decision making and problem
solving tools such as control charts, process flow diagrams, Pareto charts, and fishbone charts
are explained.
 
Learning Outcomes
On successful completion of this module the learner will be able to:
# Learning Outcome Description
LO1 Explain the approaches to, concepts, and theories of Lean Manufacturing, including key aspects of Just in Time and Six Sigma.
LO2 Apply World Class Manufacturing (WCM) techniques to effect continuous improvement.
LO3 Apply Analytical Troubleshooting (ATS) techniques to technical problem solving and decision making.
LO4 Explain people management issues and discuss how they can be addressed.
Dependencies
Module Recommendations

This is prior learning (or a practical skill) that is strongly recommended before enrolment in this module. You may enrol in this module if you have not acquired the recommended learning but you will have considerable difficulty in passing (i.e. achieving the learning outcomes of) the module. While the prior learning is expressed as named MTU module(s) it also allows for learning (in another module or modules) which is equivalent to the learning specified in the named module(s).
Incompatible Modules
These are modules which have learning outcomes that are too similar to the learning outcomes of this module. You may not earn additional credit for the same learning and therefore you may not enrol in this module if you have successfully completed any modules in the incompatible list.
9715 CHEP8019 Process Quality Management
Co-requisite Modules
No Co-requisite modules listed
Requirements

This is prior learning (or a practical skill) that is mandatory before enrolment in this module is allowed. You may not enrol on this module if you have not acquired the learning specified in this section.
No requirements listed
 
Indicative Content
Lean Manufacturing
Principles and application of Lean Manufacturing. Waste processes versus value added processes. Continuous improvement. Employee involvement. Process Analytical Technology (PAT).
Just in Time
Just in Time, scope, challenges, benefits, effect on quality, finance, and efficiency, process layouts.
Six Sigma
Principles, tools comparison of Six Sigma with Lean.
Decision Making & Technical Problem Solving
Analytical trouble-shooting techniques, SQC tools, Pareto and fishbone charts, Kepner Tregoe, SIPOC, DMAIC, Why-Why analysis, benchmarking, improvement priorities - important to customers, polar diagrams, continuous and breakthrough improvement.
Process Mapping
Following process flows and mapping processes on flowcharts. Process bottlenecks and the most effective methods to de-bottleneck. Cycle-time analysis.
People Involvement
Employee empowerment and development. Education training and development. Long term commitment. Unity of purpose. Teamwork. Accelerated change management. Influencing the organisation mindset and culture to deal with and adapt to change.
Module Content & Assessment
Assessment Breakdown%
Coursework30.00%
End of Module Formal Examination70.00%

Assessments

Coursework
Assessment Type Short Answer Questions % of Total Mark 10
Timing Week 6 Learning Outcomes 1,2,3
Assessment Description
Lean Manufacturing, WCM and ATS Techniques
Assessment Type Written Report % of Total Mark 20
Timing Week 8 Learning Outcomes 1,2
Assessment Description
Book review assignment
End of Module Formal Examination
Assessment Type Formal Exam % of Total Mark 70
Timing End-of-Semester Learning Outcomes 1,2,3,4
Assessment Description
End-of-Semester Final Examination
Reassessment Requirement
Repeat examination
Reassessment of this module will consist of a repeat examination. It is possible that there will also be a requirement to be reassessed in a coursework element.

The University reserves the right to alter the nature and timings of assessment

 

Module Workload

Workload: Full Time
Workload Type Contact Type Workload Description Frequency Average Weekly Learner Workload Hours
Lecture Contact No Description Every Week 3.00 3
Independent & Directed Learning (Non-contact) Non Contact Assignment and student study Every Week 4.00 4
Total Hours 7.00
Total Weekly Learner Workload 7.00
Total Weekly Contact Hours 3.00
Workload: Part Time
Workload Type Contact Type Workload Description Frequency Average Weekly Learner Workload Hours
Lecture Contact No Description Every Week 3.00 3
Independent & Directed Learning (Non-contact) Non Contact Assignment and student study Every Week 4.00 4
Total Hours 7.00
Total Weekly Learner Workload 7.00
Total Weekly Contact Hours 3.00
 
Module Resources
Recommended Book Resources
  • Pound, E.S., Bell, J.H. and Spearman, M.L.. (2014), Factory Physics for Managers: How Leaders Improve Performance in a Post-Lean Six Sigma World, 1st. McGraw Hill Professional, New York, p.304, [ISBN: 007182250X].
  • Mary Walton. (1991), Deming management at work, Perigee Books, New York, NY, [ISBN: 0399516859].
Supplementary Book Resources
  • Thomas Pyzdek. (2003), The Six Sigma handbook, McGraw-Hill, New York, [ISBN: 0071410155].
  • Nigel Slack, Stuart Chambers, Robert Johnston. (2007), Operations management, Prentice Hall/Financial Times, Harlow, England, [ISBN: 0273708473].
  • W. Edwards Deming. (1986), Out of the Crisis, 1. 17, Cambridge University Press, Cambridge, p.507, [ISBN: 0521305535].
  • Daniel Roos,. (2007), The Machine That Changed the World, 1. 10, Simon and Schuster, London, p.337, [ISBN: 1847370551].
  • Kenneth Blanchard, Spencer Johnson. (1983), The one minute manager, Fontana, London, [ISBN: 00063 67534].
  • Philip Crosby. Quality is Free, [ISBN: 978-0451622471].
  • Peter F. Drucker. (2006), The Effective Executive, 1. 8, Collins, New York, p.148, [ISBN: 978-0060833459].
  • Jeffrey K. Liker. (2004), The Toyota Way, McGraw-Hill, New York, [ISBN: 0071392319].
  • Dennis P. Hobbs. (2004), Lean Manufacturing Implementation, 1. 9, J Ross Publishing, Boca Raton, Florida, USA, [ISBN: 1932159142].
  • Brian K. Nunnally, John S. McConnell. Six Sigma in the Pharmaceutical Industry, [ISBN: 1420054392].
  • edited by Nikkan Kogyo Shimbun, Ltd./factory magazine; with a preface by Shigeo Shingo; publisher's foreword by Norman Bodek. (1988), Poka-yoke, Productivity Press, Cambridge, Mass., [ISBN: 0915299313].
  • J. M. Juran, Frank M. Gryna. (1993), Quality Planning and Analysis, McGraw-Hill, New York, [ISBN: 0070331839].
  • Greg Brue and Rod Howes. (2006), Six Sigma, McGraw-Hill, New York, [ISBN: 0071430083].
This module does not have any article/paper resources
This module does not have any other resources
 
Module Delivered in
Programme Code Programme Semester Delivery
CR_SGMPR_6 Higher Certificate in Science in Good Manufacturing Practice and Technology 3 Mandatory