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Course Detail

Course Name Lean Manufacturing
Course Code 15MEC335
Program B. Tech. in Mechanical Engineering
Year Taught 2019


Unit 1

ntroduction to Lean and Factory Simulation: History of Lean and comparison to other methods – The 7 Wastes, their causes and the effects – An overview of Lean Principles / concepts / tools – Stockless Production.

The Tools of Lean Manufacturing: Continuous Flow – Continuous Flow Manufacturing and Standard Work Flow – 5S and Pull Systems (Kanban and ConWIP systems) – Error Proofing and Set-up Reduction – Total Productive Maintenance (TPM) – Kaizen Event examples. Toyota production systems, Ford production systems

Unit 2

Value Stream Mapping – Current state: Preparation for building a Current State Value Stream Map – Building a Current State Map (principles, concepts, loops, and methodology) – Application to the factory Simulation scenario.

Unit 3

Value Stream Mapping – Future State: Key issues in building the Future State Map – Process tips in building the map and analysis of the customer loop, supplier loop, manufacturing loop and information loop – Example of completed Future State Maps – Application to factory simulation – Implementation of lean practices – Best Practices in Lean Manufacturing.

Text Books

  • Womack J. P., Jones D.T. and Roos D. – ‘The Machine that Changed the World: the Story of Lean Production’ – Simon & Schuster, New York – 1996
  • Liker J. K. – ‘Becoming Lean’ – Industrial Engineering and Management Press – 1998


  • Womack J. P. and Jones D. T. – ‘Lean Thinking’ – Simon & Schuster, USA – 1996
  • Rother M. and Shook J. – ‘Learning to See’ – The Lean Enterprise Institute, Brookline, USA – 2003

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