Quality and Lean Methods in Manufacturing Systems

Engineers in Manufacturing System roles are the ones responsible for individual production lines that operate from one to hundreds of machineries at a given time. They are also responsible for supplier chains, materials requirement planning, business & resource planning, process control and quality improvement of the outputs produced by their production lines.

For many years theoretical quality models have been introduced in this field to improve the operational and quality aspects of production lines. These models range from complex data collection methods to housekeeping methods using lean thinking. These models have been introduced through time by Automotive giants such Ford and Toyota as well as Quality Gurus of the manufacturing industry and ever since then they have been used worldwide by different industries.

This module will allow you to learn about the importance of quality and lean methods when operating manufacturing systems in industry. You will learn about:

1. Lean methods and techniques that improve the running of the manufacturing environment
2. Quality Management models such as PDCA, TQM supported by Lean principles such as Kaizen
3. Quality Manufacturing Process management using SPC and Six Sigma techniques

You will attend a series of lectures and tutorials which will equip you with the knowledge and skills to enable you to complete your assessment.

1. Part A worth 35% of the individual written assessment covers Learning outcomes of the module descriptor. You are to demonstrate your research skills, knowledge and understanding of a chosen lean tools addressing specific questions outlined in the assignment brief below.
2. Part B worth 35% of the individual written assessment covers learning outcome of the module descriptor. You are to demonstrate your problem solving and analytical skills using SPC and six sigma techniques in a manufacturing case study brief outline below.
3. What, How and Why the tool is implemented or introduced to the manufacturing environment?

a. Which manufacturing process layouts best suit your tool? Give an example of a manufacturing application or scenario where this tool would be implemented in the context of your work environment? (You can use pictures)

b. How does applying this tool support the lean philosophy – (elimination of waste) and improve your overall work environment and experience?

3. How this tool improves the commercial, environment and economic context of your work environment?
4. What advantages and disadvantages are seen overall? Reflect on barriers that could met when introducing such a tool. Think stakeholders as well as shop floor staff. What can you do to ensure a smoother transition?

Assessment Break Down

Part A of the written assessment covers parts of Learning outcomes of the module descriptor. You are to demonstrate your research skills of lean tools and apply knowledge found to manufacturing environment scenarios.

Specifically Learning Outcomes are covered by the first part of your written assignment:

• Knowledge and Understanding of the commercial, economic and environmental context of manufacturing process (Application)
• Ability to critique and apply results using your knowledge of lean manufacturing methods to improve manufacturing production performance and outputs.

You will be marked on knowledge and understanding, your ability to apply and reflect on this knowledge. You must use references to support your views /researchwherever appropriate.