Material, Production and Quality Management

In order to achieve good performance, maintenance strategies must be linked to production and quality strategies. This subject is therefore tailored to the operation & maintenance engineers' need for basic knowledge of production, quality, and material management in an industrial enterprise. The central theme of the topics will be
1) Introduction to production systems, Lean production, continuous improvement, systematic problem solving and Lean toolbox;
2) Customer value and quality, quality systems (TQM, Six-Sigma, ISO), statistical process control, capability, loss function, quality improvement and toolbox;
3) Quality-at-the-Source, self-check, successive check, autonomation (Jidoka), and mistake-proofing (Poka-Yoke);
4) Production efficiency, Small-lot production, SMED, bottleneck control (Theory of Constraints, ToC)
5) Lean Maintenance;
6) Production planning & control, material planning, MRP / ERP, JIT and Kanban system;
7) Production flexibility, handling of demand and production variability, Mixed-Model Production (MMP) and Production Leveling (Heijunka);
8) Material management, inventory models, ordering, ROP, safety-stock, spare parts management and supplier integration;
9) Standardized work, daily management and organizational learning.

KNOWLEDGE: The candidate will gain knowledge of
1) Production systems, materials and quality systems in a modern industrial enterprise and the connection of these with preventive maintenance.
2) Systematic problem solving, KPI-management and production efficiency, maintenance management, quality and material management.
3) Lean production and continuous improvement methods as well as quality management and defect prevention in manufacturing, equipment improvement.Lean tools 5S, SMED, visual management.
4) The principles of bottleneck control, material management, and inventory management subject to uncertainty.
5) Lean management and implementation.
SKILLS: After taking this course the candidate should be able to
1) Use Lean's methods to map the production system, define and measure the KPIs for production and quality, identify waste, and plan improvement work.
2) Design and optimize the capacity of a production line or work cell with regard to production bottlenecks and need for maintenance. The candidate can do production lot-sizing to reach optimum capacity and reduced operating costs.
3) Be able to implement a 5S scheme and manage an SMED-Kaizen project to be able to streamline a maintenance operation efficiently and continuously.
4) Design simple systems for quality management for production and equipment using statistical control charts in a spreadsheet and mapping process capability;
5) Control stock level, spare parts ordering, and safety-stock in terms of random variation in both consumption and delivery;
6) Design and implement a single MRP or kanban system;
GENERAL COMPETENCE: The course provides an introduction to how modern companies work with methods and techniques to achieve efficient production. It is emphasized that the candidate will be able to acquire general understanding of the goals and methods used by production companies to achieve flexible, safe and efficient production and that the candidate acquires the knowledge and skills that they can apply when planning and carrying out maintenance projects. The candidate has general competence for implementing Lean. The candidate has insight into a learning organization in terms of production, maintenance and quality and will be able to contribute and disseminate knowledge through interdisciplinary work in an industrial enterprise.

Activities include a combination of lectures, submitted exercises, classroom simulations, Lean games and group work as practical learning (CDIO).