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Opr 201 Lean Management

This course introduces key concepts and tools in lean manufacturing. It covers the historical evolution of the Toyota Production System and approaches to lean production processes. The course teaches how to identify sources of waste, apply tools like value stream mapping and kanban systems, and prepare manufacturing systems for continuous improvement through techniques like 5S, kaizen, and total preventive maintenance. Students will learn how to apply lean practices through case studies and assess manufacturing systems to transition from batch to lean operations.

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jeet kumar
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252 views1 page

Opr 201 Lean Management

This course introduces key concepts and tools in lean manufacturing. It covers the historical evolution of the Toyota Production System and approaches to lean production processes. The course teaches how to identify sources of waste, apply tools like value stream mapping and kanban systems, and prepare manufacturing systems for continuous improvement through techniques like 5S, kaizen, and total preventive maintenance. Students will learn how to apply lean practices through case studies and assess manufacturing systems to transition from batch to lean operations.

Uploaded by

jeet kumar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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OPR201:LEAN MANAGEMENT

L:3 T:0 P:0 Credits:3

Course Outcomes: Through this course students should be able to

• identify key requirements and concepts in lean manufacturing

• initiate a continuous improvement change program in a manufacturing organisation

• apply the tools in lean manufacturing to analyse a manufacturing system and plan for its
improvements

• manage the manufacturing system to achieve six sigma quality and sustainability

Unit I
Historical evolution of the toyota production system : bench marking the
performance of manufacturing systems, the pre-computer inventory management,
benefits of lean, historical evolution of toyota production system, software
requirements in lean practices
Unit II
Lean production processes and approaches and their techniques : importance
of focusing upon flow, workplace organization, quick change and setup reduction
methods, total preventive maintenance, poka yoke, quality improvements, standards,
levelling, visual management
The integrative interventions : kaizen, 5S, managing change, work teams, policy
deployment, TPM
Unit III
Lean production preparation : system and process assessment, value stream
mapping, sources of waste, wrench time concept, kanban methodology and its
strategies, summing up of total time
Unit IV
Concurrent engineering : concept and application, single minute exchange of dies,
concept,need and scope of technology management, design and analysis of planned
experiments, design of experiments
Value analysis : introduction to value engineering, relevance of value engineering in
modern manufacturing, process of value analysis, approaches and aim of value
engineering, providing value to customers, benefits of value engineering
Unit V
Employee involvement : teams, training, supporting and encouraging involvement,
involving people in change process, communication, importance of culture,
ergonomics study, organisational impact of lean system
Unit VI
Lean practices : case examples of lean practices in companies, lean assessment
studies, change from batch and queue system to continuous and lean system, lean
applications for line flow, lean application for job shop

References:

1. THE TOYOTA WAY FIELDBOOK by JEFFREY K LIKER AND DAVID MEIER, M.G.Hills

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