L T P C Hrs

P20MSEN03 LEAN MANUFACTURING

3 1 0 4 60

Course Objectives
 To outline the need for lean management.
 To outline the adoption of lean management.
 To highlight different techniques of lean implementation.
 To study the project selection for lean.
 To acquaint the various areas of application of lean manufacturing.

Course Outcomes
After completion of the course, the students will be able to
CO1 – Understand the objectives, key principles and implications of lean manufacturing.
CO2 – Understand the methods and tools of lean manufacturing.
CO3 – Describe the types of lean manufacturing
CO4 – Explain the characteristic of project selection for lean.
CO5 – Design and study applications of lean manufacturing.

UNIT I PRINCIPLES OF MANUFACTURING (12

Hrs)
Review of manufacturing paradigm; Objectives of lean manufacturing, key principles and implications of lean
manufacturing, traditional versus lean manufacturing characteristics; Value creation and waste elimination-
major kinds of manufacturing waste, concept of take time, continuous flow, continuous improvement, single
piece flow.

UNIT II LEAN MANUFACTURING TOOLS AND METHODOLOGIES (12 Hrs)

Values stream mapping: Current state and future state value stream mapping; Standard work: Communication
of standard work to employees, visual controls; Quality at the source, 5S principles, Total Productive
Maintenance, Changeover and setup time reduction; Production levelling -Failure mode and effect analysis,
line balancing, mistake proofing, case studies.

UNIT III GROUP TECHNOLOGY AND JUST IN TIME MANUFACTURING (12

Hrs)
Group technology philosophy: Part family, Machine cell design and analysis; JIT-Elements of JIT, Kanban,
case studies.

UNIT IV PROJECT SELECTION FOR LEAN (12

Hrs)
Resource and project selection, Selecting projects, Process mapping, Current and future value stream
mapping, project suitable for lean initiatives.

UNIT V LEAN MANUFACTURING IMPLEMENTATION (12 Hrs)

Road map for lean manufacturing implementation; Reconciling lean with other systems Lean six sigma,
integrating lean principles in ERP and PLM; Lean production in Industry 4.0: Impact of industry 4.0 on lean
production system, case studies.

Text Books
1. Paul Myerson., Lean Supply Chain and Logistics Management, first edition, McGraw Hill Education, 2012.

2. S. R. Devadasan, V. Sivakumar, “Lean and Agile Manufacturing: Theoretical, Practical and Research
futurities”, PHI, 2012.

Reference Books
1. Beata Mrugalska, Magdalena K. Wyrwicka, “Towards Lean Production in Industry 4.0”, Procedia
Engineering, 182, 2017.
2. Pascal Dennis, Lean Production Simplified, 3rd edition, Productivity Press, 2015.

Web References
1. https://www.six-sigma-material.com/Lean-Manufacturing.html
2. https://www.sfsa.org/meetings/spring12/Lean%20Manufacturing.pdf
3. International Journal of Lean Enterprise Research – Inderscience
4. International Journal of Lean Six Sigma – Emerald publishing.
5. https://nptel.ac.in/courses/112/104/112104188/