MF4007 Lean Manufacturing Syllabus:
MF4007 Lean Manufacturing Syllabus – Anna University PG Syllabus Regulation 2021
OBJECTIVE:
(1) To implement lean manufacturing concepts in the factories.
(2) Understand the distinction between mass and lean production and to be able to assess the difference in a manufacturing environment
(3) Understand the various elements of Lean systems
(4) Learn the importance of JIT
(5) Understand the various Inspection systems and effectively plan for a Lean system
UNIT I INTRODUCTION
The mass production system – Origin of lean production system – Necessity – Lean revolution in Toyota – Systems and systems thinking – Basic image of lean production – Customer focus – Muda (waste).
UNIT II STABILITY OF LEAN SYSTEM
Standards in the lean system – 5S system – Total Productive Maintenance – standardized work –Elements of standardized work – Charts to define standardized work – Man power reduction – Overall efficiency – standardized work and Kaizen – Common layouts.
UNIT III JUST IN TIME
Principles of JIT – JIT system – Kanban – Kanban rules – Expanded role of conveyance – Production levelling – Pull systems – Value stream mapping.
UNIT IV JIDOKA (AUTOMATION WITH A HUMAN TOUCH
Jidoka concept – Poka-Yoke (mistake proofing) systems – Inspection systems and zone control – Types and use of Poka-Yoke systems – Implementation of Jidoka.
UNIT V WORKER INVOLVEMENT AND SYSTEMATIC PLANNING METHODOLOGY
Involvement – Activities to support involvement – Quality circle activity – Kaizen training – Suggestion Programmes – Hoshin Planning System (systematic planning methodology) – Phases of Hoshin Planning – Lean culture
OUTCOMES:
The student will be competent
(1) To know the necessity for a Lean Manufacturing system
(2) To Differentiate between the conventional Mass production system with Lean system
(3) In effectively implement the principles of JIT
(4) To apply the Inspection tools effectively in the Lean systems
(5) To apply Hoshin planning system to create a Lean culture in Industry
REFERENCES
1. Dennis P.,” Lean Production Simplified: A Plain-Language Guide to the World’s Most Powerful Production System”, (Second edition), Productivity Press, New York,2007.
2. Liker, J., “The Toyota Way: Fourteen Management Principles from the World’s Greatest Manufacturer”, McGraw Hill, 2004.
3. Michael, L.G., “Lean Six SIGMA: Combining Six SIGMA Quality with Lean Production Speed”, McGraw Hill, 2002.
4. Ohno, T.,” Toyota Production System: Beyond Large-Scale Production”, Taylor & Francis, Inc., 1988.
5. Rother, M., and Shook, J.,’ Learning to See: Value Stream Mapping to Add Value and Eliminate MUDA”, Lean Enterprise Institute, 1999.