Using Lean to Develop a Partnership Between Students and Industry

Using Lean to Develop Partnerships between Students and Industry

Dr. Jim Keyes College of ManagementInspiring Innovation. Learn more at www.uwstout.edu

UW Stout Wisconsin’s Polytechnic University

Mission:

University of Wisconsin-Stout is a career-focused, comprehensive polytechnic university where diverse students, faculty and staff integrate applied learning, scientific theory, humanistic understanding, creativity and research to solve real-world problems, grow the economy and serve a global society.

@ACBSPAccredited #ACBSP2015

Dr. Jim Keyes College of ManagementInspiring Innovation.

UW Stout Facts

• Enrollment• 9,371 fall 2014 • 88% Undergraduate• 12% Graduate

• Programs• 44 Undergraduate• 20 Graduate

• Employment of graduates • 97.1% 2013

• Degrees Awarded 2013-2014• 1,643 Undergraduate• 289 Graduate

@ACBSPAccredited #ACBSP2015

Dr. Jim Keyes College of ManagementInspiring Innovation.

College of Management

Departments• School of Hospitality• Business• Operations and

Management• Military Science

Undergraduate Programs• Business Administration*• Retail Merchandising

and Management*• Supply Chain

Management*• Management*• Hotel, Restaurant and

Tourism Management• Golf Enterprise

Management

• Real Estate Management• Sustainable

Management

Graduate Programs• Operations and Supply

Management*• Risk Control• Sustainable

Management• Training and Human

Resource Development

@ACBSPAccredited #ACBSP2015*ACBSP Accredited Programs 2012

Lean:The process of doing more with less

• Broader range of goods

• Fewer inputs – more outputs

• Lower costs

• Higher quality

• Shortened lead times

• Continuous improvement

• Waste elimination

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Value of Lean Before..

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Value of Lean Since…

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Need for Lean Training

• 2003 survey by DemandStream 280 manufacturers • 40% of U.S. manufacturers use Lean as their primary

business strategy

• 2007 IndustryWeek/ Manufacturing Performance Institute Census of Manufactureres • 60% of manufacturers reported using lean

• 2010 Survey of Graduated students from UW Stout • 52% were using lean

@ACBSPAccredited #ACBSP2015

Need for Lean Training

• Monster.com indicated 975 “lean” positions posted in October of 2006

• The same search recently indicated 2,253 “lean” positions available

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Lean Enterprise Institute

• Working to implement Lean education in academic settings

• LEAN – Lean Education Academic Network• 30 professors in 2005 • 99 professors in 2009• 132 professors in 2015• Acknowledge lack of dedicated courses• Understand the lack of material and training• Working to develop and database to share course

material

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Applications of Lean

• Presently dominated by manufacturing, by large producers

• New Users• Small shop manufacturers• Service industries• Back-office• Sourcing• Logistics• Retail• Healthcare

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Student Audience for Lean Training

• Technology

• Engineering

• Business

• Supply Chain

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Course Development

• Utilizing the Lean training that employers presently find value in to scope the lean course.

• Five Primary Elements• Specifying Value• Identifying the Value Stream• Flow• Pull• Perfection

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Course Outline

• Definitions - Vocabulary

• Methodologies

• Standardization

• Culture

• Empowerment

• Visual control

• Application

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Using Lean to Partner with Industry

• Industry is using lean tools

• Students are learning lean

• The Polytechnic approach is application

• Natural fit to work with industry to help them improve while improving the learning of UW Stout students

@ACBSPAccredited #ACBSP2015

Course Outline

Divided between the Classroom

five weeks instruction, demonstrations and readings

nine weeks of application based learning

at Gemba working with clients

Observing, development and implementation

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Projects begin with an A3 Report

• Standardized storytelling•Not solving the problem• Identifying the issues• A plan to address the issues• Visual tool to manage the project

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Industry Project Examples

• Actual student projects from the past few years• Major and small corporation• Large and small impacts

• Always a great learning experience for both the client and students

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Results from New Layout

Steps Set Up Final Initial Steps 50 134Steps After Changes Made 32 73% Reduction 36% 46%

Test Wall Estimated Steps

50

134

32

73

0

20

40

60

80

100

120

140

160

Set Up Final

Estimated Amount of Steps

Refill Line

• Suggestion: Add a refill line to each bin.

• Benefit: Adding a refill line will alert workers when hardware levels are low and should be replenished. This will ensure that the process will not stop as a result of not having enough hardware.

@ACBSPAccredited #ACBSP2015

Pulley Assembly

• Total Non-value Added time = 13 + 6 + 7 + 90 + 4 = 120 seconds = 2 minutes

• This time is wasted with each pulley that is built

Recommendation

• Talk to supplier to discuss changes in packaging

• A reduction in this waste improves efficiency

• Less packaging should reduce cost from supplier@ACBSPAccredited #ACBSP2015

Typical Semester Corporate Projects

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• Five to six projects involving 25 to 30

• Involving three to five companies

• Usually most companies are repeat contacts

• Students adding value while gaining first hand knowledge.

Using Lean to Develop Partnerships between Students and Industry

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