Module Details

Module Code: AGRI S9012
Full Title: Lean Manufacturing
Valid From:: Semester 1 - 2024/25 ( September 2024 )
Language of Instruction:English
Duration: 1 Semester
Credits:: 10
Module Owner:: Paul Murphy
Departments: Agriculture, Food and Animal Health
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/Methodologies to identify, categorize and reduce/eliminate all forms of waste in a sustainable food manufacturing setting.
MLO3 Evaluate and improve flow by reducing/eliminating interruptions, delays and bottlenecks that they may encounter sustainable food manufacturing.
MLO4 Critically appraise the workplace layout in a manufacturing setting and incorporate Visual Management Systems to improve efficiency, reduce waste and complexity i.e. Job Simplification in various areas of the workplace. This will also develop a sustainability culture at factory level.
MLO5 Justify the appropriate problem solving methodology to identify, analyse and eliminate the Root Cause(s) of the problem(s) that may be encountered in a sustainable food manufacturing environment.
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 Work100.00%
Module Special Regulation
 

Assessments

Full-time

Course Work
Assessment Type Continuous Assessment % of Total Mark 50
Marks Out Of 0 Pass Mark 0
Timing n/a Learning Outcome 1,2,3,4,5
Duration in minutes 0
Assessment Description
An individual project involving at least two Lean tools to deliver the project.
Assessment Type Continuous Assessment % of Total Mark 50
Marks Out Of 0 Pass Mark 0
Timing n/a Learning Outcome 2,3,4
Duration in minutes 0
Assessment Description
Shared assessment with site visit to focus on areas of the indicative content and learning outcomes outlined in the CA brief and how they relate to each other in the manufacturing environment.
If the site visit is not completed then the student will be given a relevant topic to submit a written report on.
No Project
No Practical
No Final Examination

Part-time

Course Work
Assessment Type Continuous Assessment % of Total Mark 50
Marks Out Of 0 Pass Mark 0
Timing n/a Learning Outcome 1,2,3,4,5
Duration in minutes 0
Assessment Description
An individual project involving at least two Lean tools to deliver the project.
Assessment Type Continuous Assessment % of Total Mark 50
Marks Out Of 0 Pass Mark 0
Timing n/a Learning Outcome 2,3,4
Duration in minutes 0
Assessment Description
Shared assessment with site visit to focus on areas of the indicative content and learning outcomes outlined in the CA brief and how they relate to each other in the manufacturing environment. If the site visit is not completed then the student will be given a relevant topic to submit a written report on.
No Project
No Practical
No Final Examination
Reassessment Requirement
A repeat examination
Reassessment of this module will consist of a repeat examination. It is possible that there will also be a requirement to be reassessed in a coursework element.

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

 

Module Workload

Workload: Full-time
Workload Type Contact Type Workload Description Frequency Average Weekly Learner Workload Hours
Lecture Contact Related to Course Content Every Week 2.00 2
Online (non-contact) Non Contact Asynchronous contact related to indicative content Every Week 2.00 2
Practical Contact Site visit - assessment Every Week 0.50 0.5
Independent Study Non Contact Independent study Every Week 6.00 6
Directed Reading Non Contact Directed reading Every Week 6.00 6
Total Weekly Learner Workload 16.50
Total Weekly Contact Hours 2.50
Workload: Part-time
Workload Type Contact Type Workload Description Frequency Average Weekly Learner Workload Hours
Lecture Contact Related to course content Every Week 2.00 2
Online (non-contact) Non Contact Asynchronous contact related to indicative content Every Week 2.00 2
Practical Contact Site visit - assessment Every Week 0.50 0.5
Directed Reading Non Contact Directed Learning Every Week 6.00 6
Independent Study Non Contact Independent learning Every Week 6.00 6
Total Weekly Learner Workload 16.50
Total Weekly Contact Hours 2.50
 
Module Resources
Recommended Book Resources
  • 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].
  • Taiichi, O.. (2013), Workplace Management, Reprint. McGraw Hill Professional, [ISBN: 978-0071808019].
  • Taiichi Ohno. (1988), Toyota Production System, 1st. CRC Press, p.182, [ISBN: 978-0915299140].
  • Vibeke Fladkjaer Nielsen,Susanne Pejstrup. (2018), Lean in Agriculture, Productivity Press, [ISBN: 1138317705].
  • Ben Hartman. (2015), The Lean Farm, Chelsea Green Publishing, p.258, [ISBN: 1603585923].
Supplementary Book Resources
  • James P. Womack,Daniel T. Jones,Daniel Roos. The Machine That Changed the World, REprint ed.. [ISBN: 978-0743299794].
  • Munro, A. Rodrick. (2007), The Certified Six Sigma Green Belt Handbook, ASQ Quality Press, [ISBN: 978-0873896986].
  • 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 Pocket Toolbox, 1st. McGrath-Hill.
This module does not have any article/paper resources
Other Resources