March 23, 2023
Summer 2023 Course MSE 597 Lean Manufacturing
Summer 2023 Course MSE 597 Lean Manufacturing
MSE 597 LEAN MANUFACTURING SYLLABUS
Purdue University School of Materials Engineering
MSE 597 Lean Manufacturing 2022
Instructor Prof. Paul Mort, FLEX 3021B, 765-496-3450, pmort@purdue.edu
Lecture (6/12/23-08/01/23)
- Synchronous, in class, MWF, 15:30-16:20, WANG 2599
- Asynchronous video recorded lectures available via Brightspace, typically within an hour or two of the in-class lecture.
Office Hours: To be announced, or by appointment in FLEX 3021B or WebEx.
Course Description
Lean Manufacturing is about creating value. The Lean process starts with creating value for the ultimate customer which requires providing the right product at the right time for the specified price. While all manufacturing attempts to do this, what makes Lean Manufacturing distinct is the relentless pursuit and elimination of waste. Students will learn the concepts and tools of Lean which include types of waste, visual management, 5S, value stream mapping, A3, & flow and how it applies to materials systems.
The course was originally designed by Chris Owen who led Lean Project Initiatives at Alcoa Aluminum (now Arconic) in Lafayette, and has since been modified by Prof. Mort who has an industrial background with Procter & Gamble, including product development, manufacturing, process control and optimization. The course introduces Lean from an historical perspective, dives deeper into value stream mapping and optimization, and extends to Lean Product Development and Lean Startup.
Enrollment has grown to include a wider range of students, both on and off campus, having a broad range of interests including assembled-product manufacturing, materials processing, industrial engineering, engineering management, product development, systems optimization, and start-up innovation. To better meet these diverse mastery objectives, the course requirements includes:
- An individual literature survey according to student’s specific area of interest;
- A group presentation on a matrix topic where students are grouped based on content clustering of their specific interest areas.
Enduring Understandings
- To understand the distinction between Mass Production and Lean Manufacturing and to analyze a facility’s progress in the transition from Mass to Lean.
- Value Stream Mapping. The intent is to “provide lean thinkers the most valuable tool they will need to make sustainable progress in the war against muda [waste]: the value stream map”. (Rother and Shook).
- Matrix exercise. An individual deep-dive survey of a specific interest selected by each student, and a group exercise to synthesize and present elements of individual surveys clustered by topical area.
Learning Objectives
- Articulate a case for Lean. Students will be able to present an argument on why Lean is a superior environment to Mass.
- Compare and contrast the culture, organizational structure and leadership in Mass and Lean environments.
- List and describe the Types of Waste and why waste elimination is a core component of Lean Manufacturing.
- List and describe lean functionality (i.e. quality, continuous flow, pull systems, 5S, Visual Control, Kanban, etc.).
- Articulate why the “Rules in Use” were a breakthrough in understanding the Toyota Production System.
- Understand A3 thinking and draw an A3.
- Demonstrate ability to draw a Value Stream Map of an actual manufacturing process.
- Understand the similarities and differences between Lean Manufacturing and Product Development.
Prerequisites
Junior or higher standing in Engineering or Science
SEE ATTACHED SYLLABUS FOR MORE DETAILS