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
@ACBSPAccredited #ACBSP2015
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
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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
@ACBSPAccredited #ACBSP2015
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.