Welcome to the course!
Please read the instruction guide then, proceed with the learning materials and assignments. Each section below has tabs. For example- Instruction guide has “Course objective” and “Course content”. Click on the tabs to see the details of the respective tab. The active tabs are green in color.
Instruction guide
The objective of the course is to have basic understanding of Lean philosophy and Lean thinking. It helps to understand the concept of value as the basis for process development and know the different types of wastes. Besides, provide insights to both basic principles as well as common tools used in Lean process improvement. Additionally, would develop competencies in order to apply different Lean thinking tools in production development.
Course content as follows:
Introduction to Lean
Lean Thinking1
Lean thinking 2- Flow and Pull
Lean in manufacturing
Value stream mapping basics
Six Sigma Basics
Learning Materials
This section introduces the idea and history of lean, and describes what a lean enterprise is like. You’ll familiarize yourself with lean tools and concepts like 5S/6S, Kanban and Lean enterprise.
Watch the three videos, try out the 5S game and and study the lecture material carefully. After that, you can proceed to take the first mini exam.
Lecture material for the videos, provided my MIT Open Course Ware under CC license. Wacth the video until 11:50.
https://www.youtube.com/watch?v=T1K4pkhtad8
Next step: Play the 5S game! Remember to press the “start” button in the game linked below!
Learn about the lean enterprise concept. Resume watching the video until 40:50.
https://www.youtube.com/watch?v=T1K4pkhtad8
Learn about Kanbans etc. Resume watching the video until 48:00.
https://www.youtube.com/watch?v=T1K4pkhtad8
Finally, a short Kanban supermarket demo video, (after you click the below link; scroll down the page to see it)
In this section you will learn to:
- Describe the elements of a process
- Draw a process map
- Explain what constitutes value in a process
- List the five fundamental lean principles
- Describe several concepts and tools for implementing lean principles, like:
- 7 different types of waste
- Poka Yoke
This section contains three videos, two assignments and an exam. Watch the first video and complete the first assignment (the one that instructed in the video), then continue with the second video and second assignment and finish the video!
Link to the lecture material, provided my MIT Open Course Ware under CC license. You can stop watching the video at 11:45 and move on to the 1st assignment.
Do the first assignment: Andy & Sasha Hot Dog stand process description. You will find the assignment 1 in the “Assignments” section.
After finishing the first assignment, resume watching the video until 38:00 and then complete the second assignment. Again, you will find the second assignment 2 in the “Assignments” section.
In this section you will learn about flow, pull and perfection, and familiarize yourself with following terms and tools:
- Wait time
- Processing time
- Cycle time
- Takt time
- Balanced work
- Single piece flow
- Manufacturing cell
- Kanban
- Andon
- 5 whys
This section contains two videos and one assignments Watch the first video (1) and complete the assignment (the one that is instructed in the video), then continue with the second video!
Link to the lecture video, provided by MIT Open Course Ware under CC license. Watch until 09:10!
Now you may proceed to Assignment 3 located under “Assignment Section”
Finally, after the third assignment is completed, watch the lecture video until the end:
This section demonstrates how lean is being used in manufacturing. You will take a tour in new balance manufacturing facilities and see how they are utilizing lean. There is an assignment related to the video, so check the assignment out before you start to watch. There is also a separate, voluntary case study assignment.
Lean manufacturing in New Balance. Video is provided by MIT Open Course Ware under CC license. Watch the video and get started with the Assignment 4:
Lore
Assignments
Draw a process chart for Andy’s and Sasha’s hot dog process. Use the symbols presented in the video 1 and lecture material. Utilize the attachment describing the steps. Take a picture of your process and attach it here.
tip: It might be easier to draw by hand instead of drawing with some computer program. You can also use the sticky notes like in the video.
You can find the Hot Dog steps attached:
This exercise is provided by MIT Open Course Ware under CC license.
Look at the process map you drew in Assignment 1, and list three types of activities (below) from your process. No need to add any attachments here. So, go ahead and list:
Pure waste process steps
Value added process steps
Necessary waste process steps
Calculate the time in seconds for the 11 process steps and the total cycle time.
•Make sure to convert everything to time per order
•Don’t forget effects of rework
•Sum times to calculate an average cycle time for the customer to get a hotdog (order to delivery)
•Use the sheet provided earlier (also here as an attachament) and the process you draw earlier.
More instructions in the first video. Add the times to your process chart and attach it here. Write your total cycle time to the open text field.
This assignment is provided by MIT Open Course Ware under CC Lisence.
Write approximately 2-3 pages long essay about your lean observations in the New Balance Factory tour (600 words in minimum). Write a report in an essay form using your thesis layout and instructions, no question-answer type of text, no listings, full paragraphs. Remember to mark the references.
– Lean terminology, tools or principles that I heard or saw, and how were they used in practise?
– Enablers & barriers to implementing lean that were mentioned. How could they overcome the obstacles?
– Benefits from lean implementation that were explained?
– What do you think they did extremely well?
– What other lean tools/principles do you think they could have utilized and how?
– What could they still improve in your opinion?
THANK YOU FOR JOINING THE COURSE!
If you would like to contact the course teacher, please visit “ABOUT” section.