Syllabus
Introduction
“Lean and Agile Production” is a course unit designed to provide students with a comprehensive understanding of the principles and practices of lean and agile manufacturing in the industrial sector. These methodologies have been widely adopted in a range of industries, including manufacturing, logistics, and services, and are critical to achieving efficiency, flexibility, and customer satisfaction in today’s fast-paced business environment. By taking this course unit, students will learn how to apply lean and agile principles to optimize the production process, improve quality, reduce waste, and increase productivity. They will also gain practical experience in implementing these principles in real-world scenarios, using tools and techniques such as value stream mapping, kaizen, Kanban, and continuous improvement. In addition, students will learn how to leverage emerging technologies, such as robotics, artificial intelligence, and the Internet of Things, to support lean and agile production and enhance their understanding of the future of industrial production.
Total Hours
This course unit covers 100 hours, from which 28 hours lectures, 14 hours lab work, and 58 hours individual study and work.
General Objective
The general objective of this course unit on “Lean and Agile Production” is to provide students with a comprehensive understanding of the principles and practices of lean and agile production and how they can be applied in the industrial sector. Students will learn how lean and agile production methodologies can improve the efficiency, productivity, and profitability of industrial processes. They will also learn how to implement lean and agile production techniques in different industrial settings to reduce waste, increase flexibility, and respond to changing market demands. By the end of the course, students will be able to analyze and optimize industrial processes using lean and agile production tools and techniques, and make data-driven decisions that drive process improvement and innovation.
Specific Objectives / Learning Outcomes
The specific objectives and learning outcomes of the “Lean and Agile Production” course unit are:
- Understand the principles and concepts of lean and agile production and how they can be applied to improve the efficiency and effectiveness of industrial production processes.
- Analyze and identify the different types of waste and inefficiencies in industrial production processes, and develop strategies to eliminate or reduce them.
- Understand the importance of continuous improvement and how to implement a continuous improvement culture in industrial production processes.
- Understand the principles and benefits of just-in-time (JIT) and kanban systems, and how to implement them in industrial production processes.
- Understand the principles and benefits of lean six sigma and how to apply them to improve the quality and efficiency of industrial production processes.
- Understand the principles and benefits of agile production and how to apply them to improve the flexibility and responsiveness of industrial production processes.
- Analyze and identify the different types of value streams and how to optimize them to improve the overall efficiency and effectiveness of industrial production processes.
- Understand the principles and benefits of visual management and how to implement it in industrial production processes to improve communication and collaboration.
- Analyze and identify the different types of risks and uncertainties in industrial production processes, and develop strategies to mitigate them.
- Develop practical skills and knowledge on how to implement lean and agile production concepts and techniques in a real-world industrial production environment.
Professional Competencies
The professional competencies that students can expect to develop through this course unit include:
- Lean manufacturing: Students will gain an understanding of lean manufacturing principles and how they can be applied to production processes to improve efficiency and reduce waste.
- Agile methodologies: Students will learn about agile methodologies, including Agile project management, Scrum, and Kanban, and how they can be applied to industrial production to enhance flexibility, reduce lead times, and increase responsiveness to customer needs.
- Process optimization: Students will learn how to identify bottlenecks, waste, and inefficiencies in production processes and develop strategies to optimize those processes using lean and agile methodologies.
- Data analysis and visualization: Students will develop skills in data analysis and visualization to support lean and agile production processes, including data collection, analysis, and interpretation using statistical methods and visualization tools.
- Collaboration and communication: Students will learn how to work effectively in cross-functional teams and communicate effectively with stakeholders in the production process, including suppliers, customers, and management.
Cross Competencies
The cross competencies that students can develop through this course unit include:
- Problem-solving: Students will learn to identify and solve problems related to production processes by using lean and agile methodologies.
- Collaboration: Students will work in teams, developing their skills in collaboration and communication, which are essential in a lean and agile production environment.
- Communication: Students will learn to communicate effectively and efficiently with different stakeholders involved in the production process, including customers, suppliers, and employees.
- Adaptability: Students will learn how to be flexible and adapt to changes in the production process, which is essential in an agile environment.
- Innovation: Students will develop their creativity and ability to think outside the box, which is essential to continuously improve the production process.
- Continuous learning: Students will learn how to continuously learn and improve their skills to keep up with new technologies and production methodologies.
Alignment to Social and Economic Expectations
Evaluation
Assessment methods
For the lectures portion of the course unit the following assessment methods are used:
- Class participation and engagement: This include asking questions, participating in discussions, and demonstrating a strong understanding of the material.
- Quizzes or tests: These is given throughout the course to assess students’ understanding of key concepts and theories.
- Presentations: Students are required to give a presentation on a topic related to lean and agile production, demonstrating their ability to communicate complex ideas effectively.
- Written assignments: This include essays, or case studies, allowing students to apply the concepts they have learned to real-world situations.
For the lab work portion of the course, the following assessment methods are used:
- Completion of lab exercises: Students are required to complete a set of exercises throughout the course to demonstrate their understanding of the key concepts and their ability to apply them.
- Group projects: Students will work in groups to develop a project related to lean and agile production, demonstrating their ability to collaborate and apply their knowledge in a practical way.
Assessment criteria
For lectures, the assessment criteria for this course unit on the design of digital twins in industrial production are:
- Knowledge and Understanding: Assessment of the student’s ability to comprehend and apply the concepts, theories, and principles of lean and agile production.
- Analytical and Critical Thinking Skills: Assessment of the student’s ability to analyze and evaluate complex problems related to lean and agile production, and make informed decisions based on available data.
- Communication Skills: Assessment of the student’s ability to communicate ideas, theories, and solutions related to lean and agile production in a clear, concise, and effective manner.
- Teamwork and Collaboration Skills: Assessment of the student’s ability to work effectively in a team and collaborate with others to achieve common goals in lean and agile production.
- Application of Technology: Assessment of the student’s ability to apply appropriate technologies and tools to implement lean and agile production solutions.
For lab work, the assessment criteria could include:
- Technical Skills: Assessment of the student’s ability to apply the technical skills and knowledge acquired in the course to design and implement lean and agile production solutions.
- Quality of Work: Assessment of the student’s ability to produce high-quality work that meets the requirements and standards set for lean and agile production.
- Creativity and Innovation: Assessment of the student’s ability to think creatively and apply innovative solutions to design lean and agile production solutions.
- Attention to Detail: Assessment of the student’s ability to pay close attention to details and ensure that the lean and agile production solutions are accurate, complete, and well-documented.
- Time Management: Assessment of the student’s ability to manage their time effectively and deliver completed lab work within the specified timeframe.
Quantitative performance indicators to assess the minimum level of performance (mark 5 on a scale from 1 to 10)
Quantitative performance indicators to assess the minimum level of performance (mark 5 on a scale from 1 to 10) for the lectures in the Lean and Agile Production course unit include:
- Attendance and participation in class discussions – The student should attend at least 80% of the lectures and actively participate in class discussions.
- Homework and Quizzes – The student should complete all homework assignments and quizzes with a minimum score of 60%.
- Midterm Exam – The student should achieve a minimum score of 50% on the midterm exam.
Quantitative performance indicators to assess the minimum level of performance (mark 5 on a scale from 1 to 10) for the lab works in the Lean and Agile Production course unit include:
- Lab attendance and participation – The student should attend and participate in all scheduled lab sessions.
- Lab reports – The student should submit all lab reports on time, with a minimum score of 60% on each report.
- Lab assignments – The student should complete all lab assignments with a minimum score of 60%.
- Lab exams – The student should achieve a minimum score of 50% on the lab exams.
Quantitative performance indicators for the final exam to assess the minimum level of performance in the Lean and Agile Production course unit:
- Completion of a minimum number of lecture-related questions correctly – 70% of the total questions.
- The student should be able to demonstrate an understanding of the basic concepts and principles of lean and agile production, with a minimum score of 50% on multiple-choice questions or short answer questions.
- The student should be able to explain and analyze real-life case studies and their results, with a minimum score of 50% on case study analysis questions.
- The student should be able to demonstrate a basic knowledge of the tools and methodologies used in lean and agile production, with a minimum score of 50% on matching or labeling questions.
- The student should be able to apply the concepts and principles learned in the lectures to solve practical problems, with a minimum score of 50% on problem-solving questions.
- The student should be able to critically evaluate the benefits and challenges of using lean and agile production in industrial settings, with a minimum score of 50% on essay questions.
- Evidence of the ability to apply learned concepts and principles to practical scenarios, as demonstrated by the number of correctly answered application-based questions.
- Display of critical thinking skills, as evidenced by the number of correct answers to questions requiring analysis and synthesis of information.
- Overall exam performance, measured in terms of the total number of correct answers and expressed as a percentage of the total exam score. A minimum score of 50% or above is set as the benchmark for a mark of 5.
Lectures
Unit 1: Introduction to Lean Manufacturing (2 hours)
- Terminology
- History and modern applications
- Lean manufacturing model
- Benefits of lean manufacturing
Unit 2: Selection of “Parent” Parts for the Lean Manufacturing Line (2 hours)
- Establishing production capacity
- Sources for determining demand
- Documenting production process flow and establishing product family mix
Unit 3: Factors that Influence the Volume of Production (2 hours)
- Identifying the level of demand
- Establishing the tact at the production level
Unit 4: Documentation of the Production Process and Quality Criteria (2 hours)
- Product documentation
- Identification of activities that do not add value and other qualitative considerations
- Monitoring of activities
- Configuration of the manufacturing system
- Definition of the consequences of system imbalance
- Lean approach to ensure balance in production
- Calculation of resource requirements
- Definition of resources
- Physical configuration of resources
Unit 5: Assignment of Tasks at the Level of Workstations (2 hours)
- Methodologies for signaling timing in the process
- Rules for maintaining balance at the level of workstations
- Application of the 5S concept in the design of the manufacturing line
Unit 6: Kanban Strategies (2 hours)
- Kanban in process
- Single-card Kanban systems
- Multiple-card Kanban systems
- Determining the quantity of parts and the number of cards
- The disadvantages of Kanban systems
- The responsibilities of Kanban managers
- The transformation mechanism towards lean manufacturing
Unit 7: The implementation of Lean manufacturing Methodologies (2 hours)
- The organizational impact of lean manufacturing
- Lean production line management – output management to meet demand
- Establishing customer orientation policy
Unit 8: Introduction to Agile Manufacturing (2 hours)
- Terminology
- History and modern applications
- Agile manufacturing model
- Benefits of agile manufacturing
Unit 9: Product Design and Development for Agile Manufacturing (2 hours)
- Design for manufacturability
- Agile product development processes
- Managing the product development lifecycle
- Agile product testing and validation
Unit 10: Agile Manufacturing System Design (2 hours)
- Agile manufacturing system design principles
- Agile manufacturing system architecture
- Real-time control and monitoring systems
- Flexible automation and robotics
Unit 11: Agile Supply Chain Management (2 hours)
- Agile supply chain principles and practices
- Agile procurement and supplier management
- Agile logistics and distribution
- Managing the uncertainties in the supply chain
Unit 12: Agile Production Planning and Scheduling (2 hours)
- Agile production planning and scheduling techniques
- Agile capacity planning
- Agile demand planning
- Real-time production monitoring and control
Unit 13: Lean-Agile Manufacturing Integration (2 hours)
- Lean-agile manufacturing principles and practices
- Integration of lean and agile manufacturing systems
- Real-time value stream mapping and analysis
- Managing the production flow in the lean-agile system
Unit 14: Agile Manufacturing Implementation and Performance Measurement (2 hours)
- Agile manufacturing implementation strategies
- Performance measurement and evaluation of the agile manufacturing system
- Continuous improvement and innovation in agile manufacturing
- Agile manufacturing in the context of Industry 4.0
Lab Work
Unit 1: Value Stream Mapping (2 hours)
Objective: To introduce value stream mapping, identify areas for improvement, and develop an action plan to implement improvements.
- Introduction to value stream mapping.
- Mapping the current state of a manufacturing process.
- Identifying waste and areas for improvement.
- Developing an action plan to implement improvements.
Unit 2: Kaizen Events (2 hours)
Objective: To introduce kaizen events, identify areas for improvement, plan and conduct a kaizen event, and measure its impact.
- Introduction to kaizen events.
- Identifying areas for improvement.
- Planning and conducting a kaizen event.
- Measuring the impact of the kaizen event.
Unit 3: 5S Workplace Organization (2 hours)
Objective: Implement 5S and visual management methodologies in the design of the manufacturing line and assign tasks at the level of workstations.
- Introduction to the 5S methodology.
- Sort, Set in Order, Shine, Standardize, Sustain.
- Implementing the 5S methodology in a manufacturing process.
- Measuring the impact of the 5S methodology.
Unit 4: Standard Work (2 hours)
Objective: To introduce standard work, develop and document standard work processes, implement them in a manufacturing process, and measure their impact.
- Introduction to standard work.
- Developing and documenting standard work processes.
- Implementing standard work processes in a manufacturing process.
- Measuring the impact of standard work processes.
Unit 5: Visual Management (2 hours)
Objective: To introduce visual management, develop visual management tools and techniques, implement them in a manufacturing process, and measure their impact.
- Introduction to visual management.
- Developing visual management tools and techniques.
- Implementing visual management in a manufacturing process.
- Measuring the impact of visual management.
Unit 6: Continuous Improvement (2 hours)
Objective: To introduce continuous improvement, develop and implement a continuous improvement program, and measure its impact.
- Introduction to continuous improvement.
- Developing and implementing a continuous improvement program.
- Measuring the impact of the continuous improvement program.
Unit 7: Agile Manufacturing Simulation (2 hours)
Objective: To introduce agile manufacturing simulation, design and conduct a simulation, and measure its impact on participants’ understanding of agile manufacturing principles and practices.
- Introduction to agile manufacturing simulation.
- Designing and conducting an agile manufacturing simulation.
- Measuring the impact of the simulation on participants’ understanding of agile manufacturing principles and practices.
Supporting Infrastructure
To run the activity for this course unit, students will have the possibility to work in our labs with the following technologies:
- Work on a lean manufacturing line provided by Bosch, incorporating PLCs, robots, sensorics, transfer lines, quality control units, warehouses, HMIs, etc.
- Develop virtual prototypes with Visual Components