Lean Production and Quality Management

The course is obligatory in 3rd semester of the INGLOG study program (Program Course 3).

• Introduction to manufacturing and quality management - Lean principles
• Lean production methods (Small-lot production, SMED, Lean layout and material flow analysis, Group Technology and cell manufacturing, Standardized Work)
• Equipment maintenance and reliability analysis, statistical models, OEE
• Economic lot-sizing (EMQ model), lot-sizing w.r.t. capacity utilization
• Bottleneck management, production leveling & Mixed Model Production (Heijunka)
• Master Production Scheduling (MPS), Job Scheduling
• Pull production, Kanban systems
• Lean quality assurance (Quality at the Source, Mistake-Proofing, Jidoka)
• Six Sigma and capability analysis

Knowledge

By the end of the course, students will have specific knowledge about:

• principles of production planning and quality assurance
• methods to obtain a Lean production system
• equipment reliability models and maintenance strategies
• Production planning and job scheduling
• lot-sizing, bottleneck management, and pull production
• Lean approach to quality assurance and Six Sigma quality

Skills

By the end of the course, students will be able to:

• apply Lean techniques to achieve enhanced flow;
• analyze equipment reliability, and implement preventive maintenance;
• develop master production schedules (MPS), calculate economical lot-sizes, achieve high capacity utilization, apply production leveling, and mixed model production;
• design and implement Kanban systems, and standard operation procedures;
• employ Lean quality assurance tools; and
• use statistical Six Sigma tools for process capability analysis.

General skills

• Work in teams and collaboration
• Critical thinking and reflection
• Communication
• Continuous Improvement thinking

Teaching methods and activities include a combination of lectures, exercises, as well as workshops with classroom presentations, and a field trip to a production factory.