The Lean Production System: A Multidisciplinary Perspective - from Operations to Education ANABELA ALVES SHANNON FLUMERFELT DENNIS WADE PAWLEY LEAN INSTITUTE.
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The Lean Production System:A Multidisciplinary Perspective - from Operations to Education
ANABELA ALVES
SHANNON FLUMERFELT
DENNIS WADE
PAWLEY LEAN INSTITUTE
Outline
1. Objectives
2. Lean Production brief literature
3. Lean Production multidisciplinary applications
4. Lean projects advantages & benefits
5. Lean Engineering Education• Sustainability competencies• Systems competencies• Ethics competencies
6. Final remarks and some references
2
Objectives
Present some initiatives of Lean integration in curricula
Present and review Lean as a body of knowledge that provides a framework for Lean Thinking to emerge in Engineering Education (EE) – LEE and school curricula
Present Lean Engineering Education based on the holistic development model of ethics, systems and sustainability competency development
3
Lean Production is a methodology… 4
Productivity
Costs
Wastes
Respecting…
Lean Production - origins 5
Interchangeable parts
Standardized WorkTime study
Assembly line
“Doing more with less”
JITJidokaKaizenSMED
Pull system
Work Division
Statiscal Process ControlPlan-Do-Check-Act cycle
Teamwork
Lean Production
Critical phases in the LP evolution 6
Lean Production principles & some tools
7
3M: muda, muri, mura 8
Pite
l (20
08)
Muda Mura
Muri
LP implementation cases 9
Goods/services diversity
Lean Production multidisciplinary 10
Disciplinary areas 11
12Type of Lean learners
13Some organizations that advocate Lean teaching
…
Lean projects in industry by Industrial Engineering at UMinho
14
Represents an increase of slightly > 300% (supervisions by the same 5 supervisors)
(Alv
es e
t al.,
201
4)
Advantages & benefits – for companies
15
(Alv
es e
t al.,
201
4)
Advantages & benefits – for companies
16
Some benefits resulted from many waste types reduction => increased productivity
One benefit resulted from single specific waste elimination => reduced defects
Muri & mura were also reduced => e.g. improved ergonomic conditions
Additionally & most important: Greater awareness for the Lean management methodologyPromoted a culture of wastes reduction Innovation and entrepreneurshipCapacity to accommodate new projects, new perspectives and ideas from someone outside the company
(Alv
es e
t al.,
201
4)
Advantages & benefits – for students
17
Students learn in a real context Solve engineering problems, by transferring knowledge
and skills acquired during the initial training Ability to interact with an organization and its members Special communication skills due to the different profiles
and backgrounds of organization members Opportunity to link theoretical concepts to practical
situations, which are determined by a real life problem Develop transversal skills (e.g. teamwork,
communication, resilience, motivation, team leader, to be assertive, engage others)
(Alv
es e
t al.,
201
4)
Advantages & benefits – for faculty Opportunity to learn with industry and help them to grow Visit companies and do some networking Be motivated to perfect their own Lean journey Enrich database of examples, videos, problems
and solutions, which can be used in classes such as:
18
(Alv
es e
t al.,
201
4)
Advantages & benefits – for university
19
University as a whole might be credited at the long run, for mastering Lean supervisions and attain good industrial outcomes
Augmenting visibility and global recognizance is achieved through the free access to MSc database (http://repositorium.sdum.uminho.pt/?locale=en)
(Alv
es e
t al.,
201
4)
Lean Engineering Education definition
A systematic, student-centered and value-enhanced approach
to educational service delivery that enables students to
holistically meet, lead and shape industrial, individual and
societal needs by integrating comprehension, appreciation
and application of tools and concepts of engineering
fundamentals and professional practice through principles
based on respect for people and the environment and
continuous improvement
(Flumerfelt et al., 2014)
20
21Lean Engineering Education principles
(Flu
mer
felt
et a
l., 2
014)
Lean Engineering Education – competencies pulled
22
LEAN
ENGI
NEER
ING
EDUC
ATIO
N
CONTENT MASTERY
ENGINEERING EDUCATION
TARGET OUTCOMES
SYSTEMS COMPETENCY
MASTERY SUSTAINABILITY COMPETENCY
MASTERY ETHICS
COMPETENCY MASTERY
PULL FROM STUDENTS EMPLOYERS SOCIETY FACULTY
(Flumerfelt et al., 2014)
Final remarks
Lean Production is multidisciplinary & a global concept Lean Thinking is viewed as a philosophy, a mind-set of
waste-free thinking & a new paradigm that implies changes to behavior and attitudes of all stakeholders
Students from all disciplinary areas could benefit from the Lean learning because this is aligned with industry and society needs
LEE promote competences in the students giving them ability to meet demands of a high degree of complexity by content & competency master of Systems, Sustainability & Ethics
23
Some references Alves, A. C., Kahlen, Franz-Josef, Flumerfelt, Shannon, Siriban-Manalang, Anna-Bella (2013). Lean Engineering Education: bridging-
the-gap between academy and industry. In First International Conference of Portuguese Society of Engineering Education (CISPEE), cispee13_Submission40.
Alves, A. C., Sousa, R. M., Dinis-Carvalho, J., Lima, R. M., Moreira, F.,. Leão, C. P., Maia, L. C., Mesquita, D., Fernandes, S. (2014). Final year Lean projects: advantages for companies, students and academia. Proceedings of the Sixth International Symposium on Project Approaches (PAEE2014), Medellin, Colombia, 28-29 July, ID56.1-56.10. http://hdl.handle.net/1822/30172
Alves, A. C., Kahlen, Franz-Josef, Flumerfelt, S. and Siriban-Manalang, A-B. (2014). The Lean Production multidisciplinary: from operations to education. Proceedings of International Conference of Production Research Americas (ICPRAmericas), Lima, Peru, 31 July to 1 August.
ASME Board on Education, “Vision 2030: Creating the Future of Mechanical Engineering Education,” 2012
Flumerfelt, S., Alves, AC,. & Kahlen, F-J. (2013). What Lean teaches us about ethics in engineering. Procs. ASME -IMECE2013, Nov. 15-21, USA.
Flumerfelt, S., Alves, A. C. and Kahlen, F.-J. (2014). Lean Engineering Education: The DNA of Content and Competency Mastery. Proceedings of the 2014 IIE Engineering Lean and Six Sigma Conference, Lean Educator Conference, Orlando, Sept. 29-Oct. 01.
Flumerfelt, S., Kahlen F. J., Alves, A. C., Siriban-Manalang, A., Lean engineering education: Driving content and competency mastery, ASME Press, New York. 2014 (in press)
Ingenioren, 2008. Danske virksomheder peger op Aalborg Universitet som den bedste ingenøruddannelse ilandet (Danish companies point at Aalborg University as the best engineering education institution in Denmark). By Bjørn Kock Sørensen. Published, Friday the 30th of May, Number 22, 2008.
Kahlen, F-J., Flumerfelt, S., Siriban-Manalang, AB. & Alves, AC. (2011) "Benefits of Lean Teaching" Procs. ASME-IMECE2011, Nov. 12-18,USA.
Kahlen, F.-J., Flumerfelt, S., Alves, A. C., & Manalang, A. B. S. (2013). The möbius strip of Lean Engineering and Systems Engineering. Proceedings of the ASME 2013 International Mechanical Engineering Congress & Exposition (IMECE2013), November
15-21, S. Diego, California, USA. http://proceedings.asmedigitalcollection.asme.org/proceeding.aspx?articleid=1859181
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