N90403 Lean Manufacturing

Market globalization requires companies to constantly improve their performance. In recent years, a growing number of companies (regardless of their size and product characteristics) have started a renewal of their processes according to "Lean Manufacturing" principles and, accordingly, the request for young engineering graduates who are able to get involved quickly in the context of these transformation projects is increasing.

The course aims to provide the basic skills to operate in companies that want to gain competitive advantage through a streamlined transformation of their organization, obtaining quick and sustainable results.

To better understand the topics presented and carry out the activities envisaged in the course, students are required to:

• Observe
• Critical analyze the capabilities of different situations,
• Will to constantly ask questions about problems that are found and answered,
• Will to take challenges and to propose alternative solutions,
• Work in team

By the end of the course, students are able to understand which activities involved by the processes are not value-added and which are the appropriate tools and practices to by applied in order to eliminate wastes. With reference to tools and practices, students have the skills required to apply to real contexts.

After an introductory phase aimed at describing the cultural and organizational changes needed to effectively deal with the transformation, the main tools needed to identify the Value Flow (Value Stream Map), identifying the sources of waste that will allow, once eliminated, the desired improvement are presented.

Through concepts of Stability of Processes and Standardization of Work, one can understand the concept of “Just-In-Time”, achievable through the implementation of the key elements such as leveling, Pull management and the Kanban system.

The program also provides explanations of the main techniques to reduce waste or all activities that do not add value to the product, namely:

• 5S (creating workstations in order and with only the necessary tools)
• SMED (reduction of the time of attracts)
• Kaizen (continuous improvement)
• Department Layout Review (dedicated lines, mixed-line lines, and U-generation cells)

Le lezioni si svolgeranno:

• in aula, dove verranno presentate le principali metodologie, si effettueranno esercizi  e si discuteranno case study di realizzazione Lean in alcune aziende di successo internazionale
• con visite  presso aziende leader nella Produzione Lean in cui responsabili del Manufacturing faranno visitare reparti produttivi, fornendo spiegazioni riguardo l’approccio strutturato seguito per le soluzioni adottate e le criticità affrontate
• nel laboratorio sperimentale della LIUC (i-FAB) in cui si metteranno in pratica le metodologie spiegate in aula

Final written exam with exercises and closed questions as a quiz.

The same exam methodology will be adopted for the first exam date in summer 2020.