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BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE, PILANI

WORK INTEGRATED LEARNING PROGRAMMES


Part A: Content Design

Course Title Manufacturing Excellence


Course No(s) ET ZC 417
Credit Units 4
Credit Model 1+1+2
Course Author Dr. Naga Vamsi Krishna Jasti
Version No Ver 1.2
Date 16th July 2016

Course Objectives

No

CO1 To enable you to design a globally competitive manufacturing organisation using


manufacturing excellence techniques

CO2 To develop the skills to implement manufacturing excellence principles in industry and manage
the change process to achieve continuous improvement of efficiency and productivity.

CO3 To enhance knowledge of participant to develop an integrated approach to address dynamic


organizational problems

Teaching methodology: Text Book(s)


T1 Besterfield D. H., et al., "Total Quality Management", Pearson Education, 1999.

T2 Pascal Dennis, Lean production simplified, Second Edition, Productivity Press, 2007

Reference Book(s) & other resources

R1 Voss C.A. "Manufacturing Strategy: Process and Content", Chapman & Hall, London, 1992.

R2 Nicholas J.M., "Competitive Manufacturing Management", Tata McGraw Hill Publishing


Company Limited, New Delhi, 2001.

R3 Mohanty R.P. and Deshmukh S.G., Advanced Operations Management, Pearson Education,
2003.
Modular Content Structure

1. Introduction Manufacturing Excellence


1.1. Overview of Manufacturing Excellence
1.1.1. Meaning of Excellence
1.1.2. Competing in World markets
1.1.3. Justification of Manufacturing Excellence
1.2. Characteristics of Manufacturing Excellence
1.2.1. Review of literature about the concept of manufacturing excellence.
1.2.2. Need of manufacturing excellence principles
1.3. Frameworks and competitive priority of organizations
1.3.1. Definition of framework and model in manufacturing excellence
1.3.2. Review of competitive priorities for manufacturing excellence.
2. Manufacturing Strategy
2.1. Introduction to Operations strategy,
2.2. Competitive priorities
2.3. Incorporating manufacturing perspective in corporate Strategy,
2.4. Missing the links in manufacturing strategy
. 3. Introduction to Lean Manufacturing
3.1. What is lean manufacturing?
3.2. What is difference between traditional and lean manufacturing
3.3. What is difference between JIT and lean manufacturing?
3.4. Application of lean manufacturing
3.5. Evaluation of production systems
3.6. Definition of lean manufacturing
3.7. Birth of lean manufacturing
3.8. Importance of lean manufacturing
3.9. Types of wastes
3.10. System and System thinking
4. Stability
4.1. What is stability?
4.2. What is Standardized Work?
4.3. What is role of stability and standardization in lean manufacturing?
4.4. Five pillars of lean manufacturing
4.5. Pillar: Stability and its tools
Visual Management
TPM
5. Standardized work
5.1. Methods engineering versus lean thinking
5.2. What do we have to manage?
5.3. Why standardized work?
5.4. The elements of standardized work
Production capacity chart
Standardized work combination table
Standardized work analysis chart
Job element sheets
Overall efficiency and individual efficiency
Common Layouts.
6. Just in Time Production
6.1. What is Just in Time (JIT)
6.2. Why JIT?
6.3. What is role of JIT in lean manufacturing?
6.4. Basic principles of JIT
Pull Production: types
Kanban
SMED
Production levelling
Heijunka box
Value stream mapping
7. Jidoka
7.1. What is Jidoka
7.2. Why Jidoka
7.3 Application of Jidoka
7.4. Jidoka
7.5. Poka yoke
Using Poka yoke
Three paths to Poka yoke
Poka yoke detection methods
Implementation steps
Case Study
8. Introduction to Total Quality Management (TQM)
8.1. Understanding quality
8.2. Difference between quality control and TQM
8.3. Requirements of TQM
8.4. Role of TQM in Manufacturing Excellence
8.5. Elements of TQM and its role
9. Benchmarking
9.1. What is qualitative and quantitative tools in TQM
9.2. What are the uses of qualitative and quantitative tools in TQM
9.3. Introduction and definitions of Benchmarking
9.4. Types of Benchmarking
9.5. Implementation steps and process
9.6. Advantages
9.7. Case Study: Benchmarking
9.8. Develop a problem on benchmarking
10. Failure Mode Effective Analysis
10.1. What is Failure Mode Effective Analysis (FMEA)
10.2. Uses of FMEA
10.3. Applications of FMEA
10.4. To learn the steps to developing FMEAs
10.5. To summarize the different types of FMEAs
10.6. To learn how to link the FMEA to other Black Belt tools
10.7. To perform an exercise on FMEA
10.8. Case Study: FMEA
11. Quality Function Deployment
11.1. What is Quality Functional Deployment (QFD)
11.2. Uses of QFD
11.3. Applications of QFD
11.4. QFD Team
11.5. Benefits of QFD
11.6. Voice of the Customer
11.7. House of Quality
11.8 Building a House of Quality: Case Study
11.9. QFD Process
12. Management Tools in TQM
12.1. Why, Why analysis
12.2. Force Field Analysis
12.3. Nominal Group Technique
12.4. Affinity diagram
12.5. Interrelationship Digraph (ID)
12.6. Tree diagram
12.7. Matrix diagram
12.8. Prioritization Matrices
12.9. Process Decision Program Chart (PDPC)
12.10. Activity network diagram
13. Total Productive Maintenance
13.1. Evolution of maintenance
13.2. Difference between maintenance and TPM
13.3. Role of TPM in manufacturing excellence
13.4. Types of TPM
13.5. Overall equipment effectiveness
13.6. Numerical methods

Learning Outcomes:
No Learning Outcomes

LO1 Able to adapt the continuous improvement program to achieve excellence in manufacturing
functions.

LO2 Able to apply lean manufacturing and quality system tools to enhance the performance factors of
production line.

LO3 Able to conduct, analyze and interpret experiments on process models

LO4 Able to identify opportunity, study, analyze and suggest possible improvement on the production
line

LO5 Able to apply critical lean manufacturing tools to enhance the existing production line.

Experiential learning components: Lab work:-


Operations Management Exercise: Push vs. Pull Production
Description
An exercise illustrates a fundamental concept in Operations Management and can be used to
reinforce key learning objectives in case studies and readings. In this single-player exercise, students
learn about two basic production triggering mechanisms used in production planning and inventory
control, Push and Pull. Students explore the differences between these common mechanisms in the
context of a computer manufacturing supply chain that feeds a retailer. In the process they learn
about implications for meeting demand and managing inventories and capacity utilization. The
professor can select corresponding assignment questions for each process. This exercise can be used
for courses in Operations Management for both MBA and undergraduate students. It is delivered
entirely online and requires one class meeting or less for students to run the exercise and discuss the
results.
Learning objective:

1. To give students some intuition about production flow in a complex, multi-stage process, and how that
flow is affected by bottlenecks and production triggers;

2. To contrast the dynamic of Push, Pull, and mixed systems;

3. To explore the relations between batch size and set-up times in those systems.

Part B: Course Handout

Academic Term First Semester 2017-2018


Course Title Manufacturing Excellence
Course No ET ZC417
Lead Instructor Dr.Naga Vamsi Krishna Jasti

Contact Session 1
Sub Module Title: Introduction Manufacturing Excellence
Type Content Topic Title Study/HW
Ref. Resource
Reference

Pre 1.1 Importance of manufacturing systems R4


CH 1.2 What is manufacturing excellence

During 1.3 Overview of Manufacturing Excellence


CH Meaning of Excellence
Competing in World markets R4
1.4 Justification of Manufacturing Excellence
Characteristics of Manufacturing Excellence
1.5 Review of literature about manufacturing excellence.
Need of manufacturing excellence principles
1.6 Competitive priorities for Manufacturing Excellence
1.7 Frameworks for Manufacturing Excellence
Case Study to show importance of manufacturing excellence

Post 1.8 Analyze : Case Study Quiz sheet


CH 1.9 Quiz-1 questions provided by instructor (to be
provided by
instructor)

Contact session 2
Sub Module Title: Manufacturing Strategy
Type Content Topic Title Study/HW
Ref. Resource
Reference

Pre 2.1 What is need of manufacturing strategy R4


CH 2.2 Different types of manufacturing strategies and its International
significance Journal
During 2.3 Introduction to Operations strategy
CH 2.4 Competitive priorities R4
2.5 Incorporating manufacturing perspective in corporate International
Strategy, Journal
2.6 Missing the links in manufacturing strategy

Post 2.7 Assignment-1 given by instructor


CH

Contact session 3
Sub Module: Introduction to Lean Manufacturing
Type Content Topic Title Study/HW
Ref. Resource
Reference

Pre 3.1 What is lean manufacturing Online


CH 3.2 What is difference between traditional and lean Resource
manufacturing
3.3 What is difference between JIT and lean manufacturing
3.4 Application of lean manufacturing

During 3.5 Evaluation of production systems


CH 3.6 Definition of lean manufacturing
3.7 Birth of lean manufacturing
3.8 Importance of lean manufacturing
T1 Chapter 9
3.9 Types of wastes
3.10 System and System thinking

Post 3.11 Difference between developing of lean manufacturing and Quiz sheet
CH traditional production lines: Flexsim Software

Contact session 4
Sub-module Title: Stability and Standardized work
Type Content Topic Title Study/HW
Ref. Resource
Reference

Pre 4.1 What is stability Online


CH 4.2 What is Standardized work Resource
4.3 What is role of stability and standardization in lean
manufacturing

During 4.4 Five pillars of lean manufacturing T1 Chapter


CH 4.5 Pillar: Stability and its tools 15
Visual Management
4.6 Pillar: Standardized work
Methods engineering versus lean thinking
What do we have to manage?
Why standardized work?
The elements of standardized work
Post 4.7 Exercise on Standardization of work
CH

Contact session 5
Sub-module Title: Standardized work

Type Content Topic Title Study/HW


Ref. Resource
Reference

Pre 5.1 What is standard charts Online


CH 5.2 Its application Resource

During 5.4 Production capacity chart T1 Chapter


CH 5.5 Standardized work combination table 15
5.6 Standardized work analysis chart
5.7 Job element sheets
5.8 Overall efficiency and individual efficiency
5.9 Common Layouts.

Post 5.10 Exercise on Standardized charts


CH

Contact session 6
Sub-module Title: Just in Time Production

Type Content Topic Title Study/HW


Ref. Resource
Reference

Pre 6.1 What is Just in Time (JIT) Online


CH 6.2 Why JIT? Resource
6.3 What is role of JIT in lean manufacturing

During 6.4 Basic principles of JIT T1 Chapter


CH Pull Production: types 15
Kanban
SMED
Production levelling
Heijunka box

Post 6.5 Exercise on Kanban and Pull Production


CH

Contact session 7
Sub-module Title: Just in Time ProductionValue Steam Mapping
Type Content Topic Title Study/HW
Ref. Resource
Reference

Pre 7.1 What is Value Stream Mapping (VSM) Online


CH 7.2 What kind of information we are mapping in VSM Resource
7.3 Application of VSM

During 7.4 Value stream mapping T1 Chapter


CH Objectives 15
VSM Symbols
Steps in VSM
Case Study

Post 7.5 Exercise on VSM


CH

Contact session 8
Sub-module Title: Jidoka
Type Content Topic Title Study/HW
Ref. Resource
Reference

Pre 8.1 What is Jidoka Online


CH 8.2 Why Jidoka Resource
8.3 Application of Jidoka

During 8.4 Jidoka T1 Chapter


CH Poka yoke 15
Using Poka yoke
Three paths to Poka yoke
Poka yoke detection methods
Implementation steps
Case Study

Post 8.5 Exercise on Poka yokeFlexsim


CH

Contact session 9
Sub-module Title: Review
Type Content Topic Title Study/HW
Ref. Resource
Reference

Pre 9.1 Review all classes Previous


CH Classes

During 9.2 Review: complete syllabus


CH 9.3 Flexsim Assignments
Contact session 10
Sub-module Title: Introduction to Total Quality Management (TQM)
Type Content Topic Title Study/HW
Ref. Resource
Reference

Pre 10.1 What is quality Online


CH 10.2 What is Total quality management Resource
10.3 What is difference between quality control and total quality
management

During 10.4 Understanding quality


CH 10.5 Difference between quality control and TQM
10.6 Requirements of TQM T1 Chapter
10.7 Role of TQM in Manufacturing Excellence 10
10.8 Elements of TQM and its role

Post 10.9 Importance of TQM: Flexsim software Assignment to be


CH provided by
instructor

Contact session 11
Sub-module Title: Benchmarking
Type Content Topic Title Study/HW
Ref. Resource
Reference

Pre 11.1 What is qualitative and quantitative tools in TQM Online


CH 11.2 What are the uses of qualitative and quantitative tools in Resource
TQM
11.3 Introduction and definitions of Benchmarking

During 11.4 Types of Benchmarking T1 Chapter


CH 11.5 11
11.6 Implementation steps and process
11.7
Advantages
Case Study: Benchmarking

Post 11.8 Develop a problem on benchmarking Problems


CH identified in
the textbook

Contact session 12
Sub-module Title: Failure Mode Effective Analysis
Type Content Topic Title Study/HW
Ref. Resource
Reference
Pre 12.1 What is Failure Mode Effective Analysis (FMEA) Online
CH 12.2 Uses of FMEA Resource
12.3 Applications of FMEA

During 12.4 To learn the steps to developing FMEAs T1 Chapter


CH 12.5 To summarize the different types of FMEAs 11
12.6 To learn how to link the FMEA to Black Belt tools
12.7 To perform an exercise to actually perform
an FMEA
12.8 Case Study: FMEA

Post 12.9 Develop a problem on FMEA


CH

Contact session 13
Sub-module Title: Quality Functional Deployment
Type Content Topic Title Study/HW
Ref. Resource
Reference

Pre 13.1 What is Quality Functional Deployment (QFD) Online


CH 13.2 Uses of QFD Resource
13.3 Applications of QFD

During 13.4 QFD Team T1 Chapter


CH 13.5 Benefits Of QFD 11
13.6 Voice Of The Customer
13.7 House Of Quality
13.8 Building A House Of Quality: Case Study
13.9 QFD Process

Post 13.10 Case study analysis Problems


CH identified in
the textbook

Contact session 14
Sub-module Title: Management Tools in TQM
Type Content Topic Title Study/HW
Ref. Resource
Reference

Pre 14.1 What is management tool Online


CH 14.2 How management tools are helpful to improve quality of the Resource
product
14.3 What are the management tools and list all

During 14.4 Why, Why analysis


CH 14.5 Force Field Analysis
14.6 Nominal Group Technique
14.7 Affinity diagram T1 Chapter 7
14.8 Interrelationship Digraph (ID)
14.9 Tree diagram
14.10 Matrix diagram
14.11 Prioritization Matrices
14.12 Process Decision Program Chart (PDPC)
14.13 Activity network diagram

Post 14.14 Develop assignment to use all management tools


CH

Contact session 15
Sub-Module Title: Total Productive Maintenance

Type Content Topic Title Study/HW


Ref. Resource
Reference

Pre 15.1 What is maintenance Online


CH 15.2 How maintenance is useful to improve the productivity of Resource
the organization.

During 15.3 Evolution of maintenance


CH 15.4 Difference between maintenance and TPM
15.5 Role of TPM in manufacturing excellence
15.6 Types of TPM and its role
T1 Chapter
15.7 Overall equipment effectiveness
13
15.8 Numerical method

Post 15.9 Exercise problems on OEE International


CH Journal
Article

Contact session 16
Sub-module Title: Review
Type Content Topic Title Study/HW
Ref. Resource
Reference

Pre CH 16.1 Review all classes Online


Resource

During CH 16.2 Review: complete syllabus T1 Chapter


16.3 Flexsim Assignments 16
Evaluation Scheme

Evaluation Name Type Weight Duration Day, Date, Session,


Component (Quiz, Lab, Project, Mid (Open book, Time
term exam, End semester Closed book,
exam, etc) Online, etc.)

EC - 1 Quiz 15 August 26 to
September 4, 2017

EC 1 Lab Push-Pull System Online lab 10 October 20-30, 2017

EC-2 Mid Semester Closed Book 30 2 Hours 23/09/2017 (AN) 2


Examination PM 4 PM

EC-3 Comprehensive Open Book 45 3 hours 04/11/2017 (AN) 2


Examination PM 5 PM

Syllabus for Mid-Semester Test (Closed Book): Topics in Session Nos. 8


Syllabus for Comprehensive Exam (Open Book): All topics
Important links and information:
Elearn portal: https://elearn.bits-pilani.ac.in
Students are expected to visit the Elearn portal on a regular basis and stay up to date with the latest announcements and
deadlines.
Contact sessions: Students should attend the online lectures as per the schedule provided on the Elearn portal.
Evaluation Guidelines:
1. EC-1 consists of either two Assignments or three Quizzes. Students will attempt them through the course pages
on the Elearn portal. Announcements will be made on the portal, in a timely manner.
2. For Closed Book tests: No books or reference material of any kind will be permitted.
3. For Open Book exams: Use of books and any printed / written reference material (filed or bound) is permitted.
However, loose sheets of paper will not be allowed. Use of calculators is permitted in all exams. Laptops/Mobiles
of any kind are not allowed. Exchange of any material is not allowed.
4. If a student is unable to appear for the Regular Test/Exam due to genuine exigencies, the student should follow
the procedure to apply for the Make-Up Test/Exam which will be made available on the Elearn portal. The Make-
Up Test/Exam will be conducted only at selected exam centres on the dates to be announced later.
It shall be the responsibility of the individual student to be regular in maintaining the self study schedule as given in the
course handout, attend the online lectures, and take all the prescribed evaluation components such as Assignment/Quiz,
Mid-Semester Test and Comprehensive Exam according to the evaluation scheme provided in the handout.