Unit 49 Lean Manufacturing in engineering for the HND curriculum provides an introduction to the learners for a systematic approach. It has the crucial aim of minimising the manufacturing system with waste by emphasising the activities which will increase the significant value from the perspective of customers. By initiating the automotive development and industry with Toyota Japan, lean manufacturing has been broadly adopted throughout the globe in multiple industries for improving competitiveness. This unit also focuses on the significance of engineering manufacturing in operating and designing the systems. The systems successfully provide the implementations with lean principles by improving customer satisfaction, quality and productivity. Whereas, minimising the complexity and costs.
This unit covers the significant topics, including the definition of Lean manufacturing. Moreover, recognising its challenges and benefits by learning the TPS Toyota production system as a basic model. Learners will acquire the way to compare TPS with multiple generic approaches of lean and identify the common tools and techniques of lean. These techniques include waste elimination, mapping of the value stream and ongoing improvement. These tools assist in the identification of inefficiencies that include excess inventory, defects and overproduction. These techniques enable students to select the accurate method of improvement for particular problems. The course also generates communication skills among students to lead the ongoing improvement initiative with the organisation efficiently.
After getting a complete understanding of the unit, the learners will have the potential to elaborate on the principles of lean manufacturing. Furthermore, they can analyse the TPS against the methodology of broader lean. They can also apply multiple procedures with the improvement of tools. They can also get the equipment for driving the lean practices in the various sectors of industry by providing an ongoing culture of responsiveness and optimisation to the needs of customers. Unit 49 also enables learners to become strong, committed with practitioners of lean. They will also have the potential to improve the efficiency of operations with sustainable competitive advantages in the environment of manufacturing environment.
Objectives of the Unit
The crucial objectives of Unit 49 Lean Manufacturing are associated with the concepts of engineering subjects like:
- To equip learners with a detailed cognition of the core concept and principles for Lean manufacturing. It also emphasises the decreasing waste and increasing customer perspective value.
- It also makes learners able to recognise, apply and identify our it of the techniques and tools in lean. For example, kaizen, mapping of the value stream and the TPS Toyota production system to the scenarios of real-world manufacturing.
- Two generate the potential of learners fall critically analysing the potential of stakeholders and advantages for lean manufacturing implementation within the various contexts of the organisation. It also improves the skills of problem-solving and decision-making.
- To make learners prepare for effective communication, continuous improvement facilitation and leave initiative throughout departments and teams.
Learning Outcomes
The main learning outcomes of unit 49, Lean Manufacturing in the context of engineering for the HND learners, are given here.
LO1: Examine the common principles of lean manufacturing and how the implementation of a lean production system contributes to business success.
- Defining and scoping leaving manufacturing:
- The significant Lean manufacturing principles philosophy
- Lean origin
- Defining the significance of lean to the customer
- Eliminating and identifying process and material waste which add value to the perspective of customers
- Challenges and benefits of adapting lean:
- Why does the organisation consider lean philosophy adoption
- Quality customer satisfaction, productivity performance of delivery
- The advantages of the lean organisation to employees, shareholders and customers.
- Highlight the significance of lean regarding delivery cost, customer satisfaction, serving cost, Management complexity and quality.
- Implementation challenges: expectation management, management of change, motivation, supply chain, investment, empowerment, burning platform.
LO2: Evaluate the Toyota Production System against the now more widely adopted generic approaches to lean manufacturing.
- System of Toyota production
- TPS research “Toyota Production System” and analyse the fundamental components of TPS with the motivation behind generating TPS
- Contrast TPS with the recognition of production systems and theories publicised by the manufacturers of the globe: how do they differ from others, and what similarities make them common?
- What are the principles which can be adopted through manufacturing outside?
LO3: Specify a range of the process improvement tools used within lean manufacturing.
- Common techniques and tools associated with the process improvement and Lean manufacturing;
- Continuous flow, 7 wastes, jit just-in-system, kanban (pull system) activities of lean simulation, mapping of value streaming, poke Yoke, maintenance of total prevention, 5 whys (significant causes)
- PDCA plan to check act, SMED single minute exchange of die, visual management, A3 reporting.
- Selecting the tool most appropriate for improvement in tackling the problem.
- Improve quality tools and delivery.
LO4: Demonstrate effective communication skills in order to lead the process of continuous improvement across an organisation.
- Communication
- Facilitating applications of small groups and optimising one of the significant tools
- For example, A3 report, 5 why technique
- Analyse the factors which can impact the engagement within the group, change management and facilitation skills.
Assessment Criteria
The assessment criteria of the unit 49 lean manufacturing are connected to the learning outcomes of engineering, such as.
LO1: Examine the common principles of lean manufacturing and how the implementation of a lean production system contributes to business success.
- 1.1 Examine how lean manufacturing principles can improve business performance.
- 1.2 Analyse the benefits of adopting lean manufacturing.
- 1.3 Analyse the key challenges encountered when implementing lean manufacturing.
- 1.4 Critically evaluate the advantages and disadvantages of implementing a lean system.
LO2: Evaluate the Toyota Production System against the now more widely adopted generic approaches to lean manufacturing.
- 2.1 Distinguish the principles of the Toyota Production System.
- 2.2 Research alternative lean production system approaches.
- 2.3 Examine the origins of lean and specify its early applications.
- 2.4 Critically analyse alternative examples of lean production systems to determine the common principles, with reference to the Toyota Production System.
- 2.5 Critically evaluate the Toyota Production System in comparison to a researched alternative, determining the elements that are critical in making the approach successful.
LO3: Specify a range of the process improvement tools used within lean manufacturing.
- 3.1 Specify which tools are commonly associated with lean manufacturing and determine in what context they would be applied.
- 3.2 Evaluate how the most common lean tools can be applied to eliminate waste in a manufacturing process.
- 3.3 Make a supported and justified recommendation for a lean tool to be applied in addressing a specified process improvement.
LO4: Demonstrate effective communication skills in order to lead the process of continuous improvement across an organisation.
- 4.1 Demonstrate and deliver a communication approach that can be taken to manage change in an organisation.
- 4.2 Evaluate the impact of this communication approach, including an evaluation of impact on employees and personal effectiveness.
- 4.3 Critically evaluate the importance of the skills required to successfully deploy change in an organisation.
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