SUBJECT NAME Lean Operations Management

SUBJECT CODE MGT 664

The LOM course content would cover concepts that are essential in today’s
Global Business, for ‘Operational Excellence’ & Competitiveness such as LEAN-
Management, Six Sigma. Knowledge-Management, LEAN-Sixsigma in Services,
ERP II and LEAN Convergence, and Going Green with LEAN.
After a decade of High technology IT and Re-Engineering, outsourcing /
downsizing, etc. most companies are still stuck, searching for a new formula
for sustainable growth and success. By focusing on their outdated definitions
of value, managers create waste, and the economies of the advanced
countries continue to stagnate. Today there is also a corporate responsibility
for every enterprise, to contribute to Green Environment. The problem is that
Organizations are still unclear and have lost sight of value for the customer and
how to create it. Today’s Global Challenges in Business are mainly Value
SUMMARY/ Creation for customer as well as society and Green environment. Present
OVERVIEW customer expectations are very high and customers look at value as well as
agility and response from the Company.
What's needed is to clearly specify value and eliminate waste, to line up all the
value-creating activities for a specific product along a value stream, and to
make value flow smoothly at the pull of the customer in pursuit of perfection.
This process should also Contribute to Green as a part of focused efforts to
eliminate wastes. In this Context Lean Operations Management clearly
demonstrates, as to how Value can be crated for the customers as well as the
society for Green initiatives
LEAN –Sixsigma fusion has clearly demonstrated Multiple Benefits for the
Enterprise both in terms of Customer Values, Speed of response and Six Sigma
Quality. The dramatic benefits seen in Services Sector make it a preferred
strategy for most of the Organization, especially the Healthcare companies.
 Understand basic principles of Lean Operations Management, as
applied to POM / SCM - Production Operations /Supply Chain
Management
 Understand Lean Management Principles, methodologies and tools
like Value Stream Maps.
 Understand the concept of SMED and Set-up TimeReduction,
principles of set-up time reduction
 Understand TPS (Toyota Production System) and its importance for
AIMS
achieving a World Class Manufacturing practices in the
Organization with related Case Studies presented as Video podcast
 Understand LEAN and Six Sigma association for Competitive
Excellence and Lean Six Sigma Strategy in Non-Manufacturing
Sector as ITES, Retail, and Healthcare etc…with real life Indian
Video case studies
 Understand as to how LEAN and Six Sigma would contribute to
GREEN Initiatives and improve the Enterprise “Environmental foot

1
 print’, concepts of Carbon footprint and Carbon credits.
 Understand concepts of ERP II and LEAN association and
Emerging technology of LEAN-SIXSIGMA-IT-ERP-KM
(Knowledge Management) convergence
 Overall Develop Skills and Competence in understanding Business
Processes, Value Stream Mapping and Value Creation for Customer
and Elimination of Wastes with LEAN-Six sigma practices

CORE LEARNING OUTCOMES

LEARNING OUTCOMES
SL.NO On completion of this unit you should be
able to:
To develop skills of analyzing core and
1 support business processes in terms of
VALUES for Customers and Wastes
To Analyse existing Processes and prepare
2 analysis, VSM Tools, VSM Symbols and
VALUE STREAM MAPPING
To be able to Develop approach and
methodology to implement 5s and
3 extensions as 6S for the company
ASSESSMENT CRITERIA
To achieve the learning outcome you must
demonstrate the ability to:
Understanding clearly What is CUSTOMER VALUES
and what is WASTES and be able to Identify 7+1=8
Wastes in processes
Understanding VSM Principles, Flow Charts,
VSM software
Clear understanding of 5S Principles and its
extensions of 6S with related methodology

Clear understanding of JIT/PULL/TAKT TIME

To be able to analyse and Develop an .KANBAN/E KANBAN principles and
4 approach methodology to implement JIT applications
/KANBAN/ E KANBAN
To be able to Analyse and develop a plan to Understanding Customer Values and Wastes in
implement LEAN SCM and identifications LEAN SCM and understanding Supply Chain
of Wastes in SCM Flow response Matrix to improve SCM flow
5
Identify GREEN Initiatives as a part of LEAN Conceptual Understanding of GREEN
SCM to improve Green Environmental Environmental foot print per unit of output as
footprint Co2-KGe
To identify and develop application Understanding core principles ,systems and
portfolio to improve processes with ERP II / methodologies associated with ERP II / LEAN
6 SIX SIGMA / KM etc..
LEAN-SIX SIGMA / Knowledge
Management for the Organization
7

2

APPROACH TO LEARNING
ASSESSMENT STRATEGY
The teaching methods will consist of formal lectures, case study
analysis, Video Podcast of real Life cases, Group Discussion and
Student Role Play in case Discussions.
As a part of learning Process Students are expected to make
Presentations and present Original Ideas and concepts for LEAN
Operations and improvements.
As is appropriate at Masters’ level, students will also be expected to
read beyond texts assigned, and to identify on their own further
sources of information for complementing their studies.
Student valuation will be based on Class Room Participation and Case
Study Discussions, Classroom Learning Initiative and attention,
discipline, Student Original Presentations on LEAN MANAGEMENT
CASE Studies, Student Project work, assignments and periodic SPOT
QUIZ on LOM Subject Content. Based on these students will be
evaluated and assigned marks .Also During Term and Final end term
examinations will be another important evaluation criteria where
questions would be more OBJECTIVE to evaluate student
understanding , than class room subjective contents.

ASSESSMENT DESCRIPTION OF WEIGHT DURATION AND MARKS

NO
METHOD ASSESSMENT METHOD % OF EXAMINATION)
1 DSA Written examination 20 2 hours and 50 Marks
2 AT Class attendance 5 Throughout the course
Case study/ Assignments,
Presentation on various
CS / PR / OR /
3 topics, Viva- voce/ Quiz, 25 Throughout the course
CP
Participation in class
activities
4 Semester End Written 50 3 hours and 100 marks
Examination Examination

Outline Teaching Schedule

Unit
Topic
Number
I Basic concepts of LEAN / LOM / Case Study examples DELL / McDonald cases 2
II Pillars of LEAN Concepts /JIT/KANBAN/ KAIZEN /Case studies 3

3
 Toyota House diagram Concepts/ TPS ( Toyota production system)/ 14 9
Rules of TPS/ Case Studies of LEAN Practices/ What not to do Toyota way/
III Toyota eight million vehicles recall issues/ Effect of Toyota issues on LEAN
principles/ Hero 9 Honda/ Titan – examples/ concepts of TQM/ TPM/
Single piece flow/ LEAN Vs Other Methods/ cases.
IV Value stream /concepts /software/ VSM Class room exercises/ case studies 3
V Lean six sigma in services / case study/six sigma principles and case 3

ERP II/ concepts/ convergence/ ERPII-LEAN-SIXSIGMA/ KM/ 3

VI
Application in health care
Concepts of knowledge management/ LEAN SCM/ LEAN and GREEN 4
VII
etc/Make Award case

Recommended Resources

Essential Textbook:
Lean Thinking - Banish waste and create wealth in your corporation by James P. Womack, Daniel
T. Jones , 2nd Ed; 2003: Free Press Edition (A division of Simon and Schuster Inc) or
Lean Transformation – How to change your business in to a lean enterprise By Bruce A Henderson
and Jorge L Larco – The Oaklea Press
Reference Books :
1) The Toyota Way By Jeffery K Liker; Tata Mcgraw Hill Publication Student
Paperback Ed.
2) Lean Six Sigma For Service- By Michael L George; Tata Mcgraw Hill Publication
Paperback Ed
3) Lean Six Sigma Demystified By Jay Arthur; Mcgraw Hill Publication Student
Paperback Edition
4) 4) Implementing A Lean Management System ( Corporate Leadership) By
Thomas Lindsay Jackson, Karen R. Jones; Productivity Press
5) Lean Manufacturing Implementation by Dennis Hobbs; APICS Publication
6) Design & Analysis Of Lean Production Systems By-Ronald-Askin-&-Jeffrey- Goldberg; John
Wiley Publication
7) Leading The Lean Enterprise Transformation by George-Koenigsaecker; Productivity Press Book
,Isbn- 13:978-1-56327-382-7 (0)
Recommended Journals:
Lean Management Journal - www.leanmj.com
Industry Week Journal - www. Industryweek.com
International Journal of Lean thinking - www.thinkinglean.com
APICS Journal - www.apics.org
Useful resources on internet:
www.lean.org
www.help.sap.com
E-learning site : elearning.alliance.edu.in