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

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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:

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(Alv

es e

t al.,

201

4)

Advantages & benefits – for university

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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

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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

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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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