Lean Manufacturing Sankar Sengupta Robert Van Til Industrial

Lean Manufacturing Sankar Sengupta & Robert Van Til Industrial & Systems Engineering Dept. Oakland University Rochester, MI 48309 (248) 370 -2211 vantil@oakland. edu 1

Research Team • Dr. Sankar Sengupta, Associate Professor Ø Expertise in Productions Systems, Quality Control, CIM, CAD, Modeling and Simulation. • Dr. Robert Van Til, Professor Ø Expertise in Modeling of Manufacturing Systems, Robotics, and Control Theory. 2

Overview of Our Research • Modeling and analysis of discrete part manufacturing systems. Ø Both simulation models & analytic models. Ø Models used to improve the performance of the manufacturing systems. - Reduce waste from excessive Work-In-Progress (WIP). - Identification and elimination of bottlenecks 3

Collaboration • We collaborate with Oakland University’s Pawley Institute for lean manufacturing. Ø Founded by Dennis Pawley, former Executive Vice President of Manf. , DCX Ø Kevin Yamada, Director of the Institute Ø The institute’s focus is on education and research concerning lean manufacturing. 4

Lean - The 7 Wastes 1. Over Production 2. Waiting 3. Transportation 4. Over Processing 5. Inventories and WIP 6. Motion 7. Defects or Rework 5

Lean Research Projects • Automatically maintain discrete part simulation models. Ø Simulation Model Maintenance Tool (SMMT). Manufacturing System SMMT Simulation Model Production Data Productivity Toolbox Value-added Information Training Data 6

Lean Research Projects • Predictive models for discrete part manufacturing systems. Ø When to perform preventive maintenance on machines during production. • Supply Chain Projects. Ø Design of an efficient supply chain network. Ø Dynamic behavior of a supply chain (tactical & operational level). Ø Optimal distribution of pipeline inventory. 7

Lean Educational Activities • Graduate course - ISE 581 Lean Principles and Application. Ø Interdisciplinary course with students from Engineering, Business, and Human Resource Development (HRD). - Students conduct a term-project with a local manufacturing company. Ø Course team-taught by faculty from these three schools. 8

Lean Educational Activities • Undergraduate course - ISE 484 Flexible Manufacturing Systems. Ø Engineering students work with HRD students on an interdisciplinary lean manufacturing project. - HRD students from HRD 310 Instructional Design course. • Possible to conduct a lean manufacturing workshop or short course for your company. Ø Either on-site or at Oakland University. 9