The Lean Production System A Multidisciplinary Perspective from

The Lean Production System: A Multidisciplinary Perspective from Operations to Education ANABELA ALVES SHANNON FLUMERFELT DENNIS WADE PAWLEY LEAN INSTITUTE University of Minho School of Engineering Department of Production and

Outline 1. 2. 3. 4. 5. 2 Objectives Lean Production brief literature Lean Production multidisciplinary applications Lean projects advantages & benefits Lean Engineering Education • Sustainability competencies • Systems competencies • Ethics competencies 6. Final remarks and some references

Objectives 3 Ø Present some initiatives of Lean integration in curricula Ø Present and review Lean as a body of knowledge that provides a framework for Lean Thinking to emerge in Engineering Education (EE) – LEE and school curricula Ø Present Lean Engineering Education based on the holistic development model of ethics, systems and sustainability competency development

Lean Production is a methodology… T I M W O O D 4 Costs Productivity U E Wastes Respecting… $

Lean Production - origins Work Division 5 Teamwork Interchangeable parts Standardized Work Time study Assembly line “Doing more with less” Statiscal Process Control Plan-Do-Check. Act cycle Lean Production JIT Jidoka Kaizen SMED Pull system

Critical phases in the LP evolution 6 • Henry Ford designed the Ford Production System - FPS 1927 193719782014 • 1937 – Toyoda company (later Toyota Motor Company) • Kiichiro and Eiji Toyoda, with Taiichi Ohno studied the FPS and improved the principles and tools of Toyota Production System (TPS). JIT - pillar of TPS • 1973 – 1 st oil crisis affects US companies and motivates interest in new Japanese manufacturing practices. • 1977 - 1 st academic paper on Kanban, JIT production and leveling • 1978 – Ohno published TPS in Japanese. He credits FPS and the American supermarket for his ideas on just in time thinking. • 1984 – NUMMI: joint venture between TMC e a GM opens in California • Mid 80 – Books published on TPS from Monden and Ohno • 1988 – Krafcik coins the term “Lean Production” to designate TPS • 1990 – The book “The machine that changed the world” (Womack, Jones and Roos) is published • Mid 90 – Several papers and books related with JIT, TQM, Lean Thinking (Womack and Jones) were published • 2000… – Others related publications appears (Lean Solutions, Lean services, …) Adapted from Shah and Ward (2007)

Lean Production principles & 7 some tools 5. Pursue perfection to eliminate mura and muri through continuous improvement 4. Allow pull of the customer 3. Create flow 2. Identify the value stream (the process) providing the value and remove the muda 1. Determine value from the perspective of the customer

3 M: muda, muri, mura Pitel (2008) Muda Muri 8

LP implementation cases Goods/services diversity 9

Lean Production multidisciplinary 10

Disciplinary areas 11

Type of Lean learners 12

Some organizations that advocate Lean teaching 13 …

(Alves et al. , 2014) Lean projects in industry by Industrial Engineering at UMinho 14 Represents an increase of slightly > 300% (supervisions by the same 5 supervisors)

(Alves et al. , 2014) Advantages & benefits – for companies 15

Advantages & benefits – for companies 16 v Some benefits resulted from many waste types reduction => increased productivity v One benefit resulted from single specific waste elimination => reduced defects v Muri & mura were also reduced => e. g. improved ergonomic conditions (Alves et al. , 2014) Additionally & most important: q Greater awareness for the Lean management methodology q Promoted a culture of wastes reduction q Innovation and entrepreneurship q Capacity to accommodate new projects, new perspectives and ideas from someone outside the company

(Alves et al. , 2014) Advantages & benefits – for students 17 Ø Students learn in a real context Ø Solve engineering problems, by transferring knowledge and skills acquired during the initial training Ø Ability to interact with an organization and its members Ø Special communication skills due to the different profiles and backgrounds of organization members Ø Opportunity to link theoretical concepts to practical situations, which are determined by a real life problem Ø Develop transversal skills (e. g. teamwork, communication, resilience, motivation, team leader, to be assertive, engage others)

Advantages & benefits – for faculty Opportunity to learn with industry and help them to grow v Visit companies and do some networking v Be motivated to perfect their own Lean journey v Enrich database of examples, videos, problems and solutions, which can be used in classes such as: (Alves et al. , 2014) v 18

Advantages & benefits – for university 19 (Alves et al. , 2014) q University as a whole might be credited at the long run, for mastering Lean supervisions and attain good industrial outcomes q Augmenting visibility and global recognizance is achieved through the free access to MSc database (http: //repositorium. sdum. uminho. pt/? locale=en)

Lean Engineering Education definition 20 A systematic, student-centered and value-enhanced approach to educational service delivery that enables students to holistically meet, lead and shape industrial, individual and societal needs by integrating comprehension, appreciation and application of tools and concepts of engineering fundamentals and professional practice through principles based on respect for people and the environment and continuous improvement (Flumerfelt et al. , 2014)

21 (Flumerfelt et al. , 2014) Lean Engineering Education principles

Lean Engineering Education – competencies pulled 22 (Flumerfelt et al. , 2014)

Final remarks 23 Lean Production is multidisciplinary & a global concept Lean Thinking is viewed as a philosophy, a mind-set of wastefree thinking & a new paradigm that implies changes to behavior and attitudes of all stakeholders Students from all disciplinary areas could benefit from the Lean learning because this is aligned with industry and society needs LEE promote competences in the students giving them ability to meet demands of a high degree of complexity by content & competency master of Systems, Sustainability & Ethics

Some references 24 Alves, A. C. , Kahlen, Franz-Josef, Flumerfelt, Shannon, Siriban-Manalang, Anna-Bella (2013). Lean Engineering Education: bridging-the-gap between academy and industry. In First International Conference of Portuguese Society of Engineering Education (CISPEE), cispee 13_Submission 40. Alves, A. C. , Sousa, R. M. , Dinis-Carvalho, J. , Lima, R. M. , Moreira, F. , . Leão, C. P. , Maia, L. C. , Mesquita, D. , Fernandes, S. (2014). Final year Lean projects: advantages for companies, students and academia. Proceedings of the Sixth International Symposium on Project Approaches (PAEE 2014), Medellin, Colombia, 28 -29 July, ID 56. 1 -56. 10. http: //hdl. handle. net/1822/30172 Alves, A. C. , Kahlen, Franz-Josef, Flumerfelt, S. and Siriban-Manalang, A-B. (2014). The Lean Production multidisciplinary: from operations to education. Proceedings of International Conference of Production Research Americas (ICPRAmericas), Lima, Peru, 31 July to 1 August. ASME Board on Education, “Vision 2030: Creating the Future of Mechanical Engineering Education, ” 2012 Flumerfelt, S. , Alves, AC, . & Kahlen, F-J. (2013). What Lean teaches us about ethics in engineering. Procs. ASME -IMECE 2013, Nov. 15 -21, USA. Flumerfelt, S. , Alves, A. C. and Kahlen, F. -J. (2014). Lean Engineering Education: The DNA of Content and Competency Mastery. Proceedings of the 2014 IIE Engineering Lean and Six Sigma Conference, Lean Educator Conference, Orlando, Sept. 29 -Oct. 01. Flumerfelt, S. , Kahlen F. J. , Alves, A. C. , Siriban-Manalang, A. , Lean engineering education: Driving content and competency mastery, ASME Press, New York. 2014 (in press) Ingenioren, 2008. Danske virksomheder peger op Aalborg Universitet som den bedste ingenøruddannelse ilandet (Danish companies point at Aalborg University as the best engineering education institution in Denmark). By Bjørn Kock Sørensen. Published, Friday the 30 th of May, Number 22, 2008. Kahlen, F-J. , Flumerfelt, S. , Siriban-Manalang, AB. & Alves, AC. (2011) "Benefits of Lean Teaching" Procs. ASME-IMECE 2011, Nov. 12 -18, USA. Kahlen, F. -J. , Flumerfelt, S. , Alves, A. C. , & Manalang, A. B. S. (2013). The möbius strip of Lean Engineering and Systems Engineering. Proceedings of the ASME 2013 International Mechanical Engineering Congress & Exposition (IMECE 2013), November 15 -21, S. Diego, California, USA. http: //proceedings. asmedigitalcollection. asme. org/proceeding. aspx? articleid=1859181