Study-Unit Description

Study-Unit Description


TITLE Lean and Agile Manufacture

LEVEL 05 - Postgraduate Modular Diploma or Degree Course


DEPARTMENT Industrial and Manufacturing Engineering

DESCRIPTION Lean manufacturing concepts enable companies to remain competitive, innovative, and profitable. However, there are new challenges facing manufacturers, namely:
- Global competition is intensifying.
- Customers expect low volume, high quality, and custom products.
- Very short product life cycles, development time, and production lead times are required.

Considering the scenario above, it is therefore not only important to have mastered the methods of world class manufacturing including lean manufacturing, but also forward looking, highly competitive organizations need to introduce agility if they want to have a chance to remain competitive. Agile manufacturing techniques are therefore perceived as the manufacturing systems of the future. In view of the above this study unit covers the following topics:

- Modelling Manufacturing System Behaviour.
- Introduction to Lean/ Agile Manufacturing.
- Waste Identification and Elimination.
- Fundamentals of Continuous Improvement.
- Small Lot Production.
- Set-up Time Reduction (SMED).
- Introduction to Total Productive Maintenance.
- TPM Pillars and Implementation of TPM.
- Focused Factories and Group Technology.
- Workcells and Cellular Manufacturing.
- Manufacturing Control Systems.
- 5 S Workplace Organization.
- Standard Operations.
- Lean Implementation.
- Overview of Agile Manufacturing.

Study-unit Aims:

The overall aim of this study-unit is to provide an understanding of the characteristics of internationally competitive manufacturing systems and knowledge of, and in particular experience in using, the lean/agile manufacturing philosophy and techniques.

Learning Outcomes:

1. Knowledge & Understanding:

By the end of the study-unit the student will be able to:
- Apply Lean/ Agile manufacturing philosophies and the respective tools/enablers.
- Use the appropriate methodologies/ tools for the practical and detailed realisation of a newly designed or an improved redesigned lean/ agile manufacturing system.

2. Skills:

By the end of the study-unit the student will be able to:
- Employ an integrated approach to efficient manufacturing system design.
- Carry out a manufacturing system analysis / design/ redesign process through the use of appropriate lean tools/ methodologies and simulation techniques.

Main Text/s and any supplementary readings:

- Womack JP. et al , Lean Thinking, 2003, Simon and Schuster, ISBN: 0743249275.
- Monden Y., Toyota Production system: An Integrated Approach to Just in Time, 1998, Engineering & Management Press, ISBN: 0898061806.
- Allen J. et al, Lean Manufacturing - A Plant Floor Guide, 2001. ISBN: 0872635252.
- Law, A.M., Kelton W.D. Simulation, Modeling and Analysis, ISBN :0070592926.

STUDY-UNIT TYPE Lecture and Independent Study

Assessment Component/s Assessment Due Resit Availability Weighting
Examination (1 Hour) SEM1 Yes 25%
Assignment SEM1 Yes 75%

LECTURER/S Emmanuel Francalanza
Pierre Vella (Co-ord.)

The University makes every effort to ensure that the published Courses Plans, Programmes of Study and Study-Unit information are complete and up-to-date at the time of publication. The University reserves the right to make changes in case errors are detected after publication.
The availability of optional units may be subject to timetabling constraints.
Units not attracting a sufficient number of registrations may be withdrawn without notice.
It should be noted that all the information in the description above applies to study-units available during the academic year 2020/1. It may be subject to change in subsequent years.