Module Details

Module Code: AGRI S8Z10
Full Title: Lean: Principles & Methodologies
Valid From:: Semester 1 - 2019/20 ( June 2019 )
Language of Instruction:English
Duration: 1 Semester
Credits:: 5
Module Owner:: Richard Crowley
Departments: Unknown
Module Description: The student will gain up to date knowledge and comprehension of the key lean principles and tools needed to add value (for the customer), improve flow and eliminate all forms of waste.
 
Module Learning Outcome
On successful completion of this module the learner will be able to:
# Module Learning Outcome Description
MLO1 Appraise the philosophy and guiding principles underpinning the Toyota Production System (TPS)
MLO2 Apply proven Lean Tools/Metodologies to identify, categorise and reduce/eliminate all forms of waste.
MLO3 Evaluate and improve flow by reducing/eliminating interruptions, delays and bottlenecks.
MLO4 Critically appraise the workplace layout and incorporate Visual Mangement Systems to improve efficiency, reduce waste and complexity i.e. Job Simplification.
MLO5 Justify the appropiate problem solving methodology to identify, analyse and eliminate the Root Cause(s) of the problem(s).
Pre-requisite learning
Module Recommendations
This is prior learning (or a practical skill) that is strongly recommended before enrolment in this module. You may enrol in this module if you have not acquired the recommended learning but you will have considerable difficulty in passing (i.e. achieving the learning outcomes of) the module. While the prior learning is expressed as named DkIT module(s) it also allows for learning (in another module or modules) which is equivalent to the learning specified in the named module(s).
No recommendations listed
 
Module Indicative Content
Toyota Production System (TPS)
Toyota's Five Guiding Principles underpinning TPS. Adding Value for the customer. Value Stream Mapping (VSM). How to eliminate Non Value activities using Lean Tools such a MUDA, Five S, JIT?KANBAN, PY, VM etc.
Waste reduction and continuous improvement
Application of modern production philosophy and techniques to drive the business in a way that ensures it meets present and future needs. For example, waste idenification and elimination (MUDA). Continuous Improvement through Teamwork (e.g. Kaizan).
Lean Tools
Discover the “The Hidden Factory/Farm” using tools such as Overall Equipment Efficiency (%OEE). Strive for Perfection e.g. The Six Sigma Approach, Visual Management, Five S etc. Standardisation of complex tasks and proceses
Zero inventory - matching production to demand
Inventory management using a PULL not Push philosophy i.e.Just In Time (JIT) and KANBANs i.e. the goal is to have a Zero Inventory approach.
Problem solving and Root Cause Analysis (RCA)
Practical Problem Solving i.e. Find, Fix and Eliminate the problem using a systematic approach. For example using the PDCA system or the 8 Disciplines (8D)of problem solving and other tools such as Failure Mode Effect Analysis (FMEA) the 5 WHY approach, and Poyke Yoke etc.
Module Assessment
Assessment Breakdown%
Course Work60.00%
Project40.00%
Module Special Regulation
 

Assessments

Full Time On Campus

Course Work
Assessment Type Class Test % of Total Mark 20
Marks Out Of 0 Pass Mark 0
Timing S1 Week 4 Learning Outcome 1,2
Duration in minutes 0
Assessment Description
n/a
Assessment Type Class Test % of Total Mark 40
Marks Out Of 0 Pass Mark 0
Timing End-of-Semester Learning Outcome 3,4,5
Duration in minutes 0
Assessment Description
The test will assess at a minimum learning outcomes not assesses in either the first Class Test or the Group Project
Project
Assessment Type Group Project % of Total Mark 40
Marks Out Of 0 Pass Mark 0
Timing S1 Week 6 Learning Outcome 2,3,5
Duration in minutes 0
Assessment Description
Implementation of VMS into a typical large scale farm to aid work simplification and to categorise and reduce waste.
No Practical
No Final Examination

DKIT reserves the right to alter the nature and timings of assessment

 

Module Workload

Workload: Full Time On Campus
Workload Type Contact Type Workload Description Frequency Average Weekly Learner Workload Hours
Lecture Contact Related to course content Every Week 3.00 3
Tutorial Contact Related to course content Every Week 1.00 1
Directed Reading Non Contact Related to course content and project Every Week 1.00 1
Independent Study Non Contact No Description Every Week 1.00 1
Total Weekly Learner Workload 6.00
Total Weekly Contact Hours 4.00
This module has no Part Time On Campus workload.
 
Module Resources
Recommended Book Resources
  • Keegan. R, O’ Kelly. E.. (2004), Applied Benchmarking for Competitiveness, 1st. Oak Tree Press, [ISBN: 978-1860762710].
  • Taiichi, O.. (2013), Workplace Management, Reprint. McGraw Hill Professional, [ISBN: 978-0071808019].
  • Kearney,M., Florida,R.. (1993), Beyond Mass Production, Oxford University Press.
  • Waterman, H. Robert, Peters, Tom. (2004), In Search of Excellence: Lessons from America's Best-Run Companies, 2nd. Profile Books, [ISBN: 978-1861977168].
  • Peters, Tom. (2012), The Little Big Things: 163 Ways to Pursue Excellence, 1st. Harper Business, [ISBN: 978-0061894107].
Supplementary Book Resources
  • Harvard Business School Press. (2009), Harvardv Business Review on Manufacturing Excellence at Toyota, p.224, [ISBN: 978-1422179772].
  • Liker, Jeffery. (2004), The Toyota Way, Reissue edition. McGrath-Hill Professional, [ISBN: 978-0071392310].
  • Taiichi, O .. (1988), Toyota Production System; Beyond Large- Scale Production, 1st. Productivity Press, [ISBN: 978-0915299140].
  • Womac, P. James, Jones, T. Danial, Roos, Danial.. (2007), The Machine that Cjanged the World, REprint ed.. Free Press, [ISBN: 978-0743299794].
  • Imai, Masaaki. (2004), Gemba Kaizan, 1st. McGrath-Hill, [ISBN: 978-0070314467].
  • Liker, Jeffery, Franz, K. James. (2011), The Toyota Way to Continuous Improvement., 1st. MCGrath-Hill Professional, [ISBN: 978-0071477468].
  • George, L. Michael, Rowlands, T. David, Kastle Bill. (2003), What is Lean Sigma, MCGrath-Hill Professional, [ISBN: 978-0071426688].
  • George, L. Michael. (2004), The Lean Six Sigma Poket Toolbox, 1st. McGrath-Hill.
  • Munro, A. Rodrick. (2007), The Certified Six Sigma Green Belt Handbook, ASQ Quality Press, [ISBN: 978-0873896986].
This module does not have any article/paper resources
Other Resources