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Course Detail

Course Name Lean Manufacturing
Course Code 19MEE342
Program B. Tech. in Computer and Communication Engineering
Year Taught 2019


Unit 1

Introduction 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 – FPS gear model

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.

Textbook / Reference


  • Womack, J.P., Jones, D.T., and Roos, D.,‘The Machine that Changed the World’, Simon & Schuster, New York, 2007.
  • Liker, J.K., ‘Becoming Lean’, Industrial Engineering and Management Press, 1997.


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

Evaluation Pattern

Assessment Internal External
Periodical 1 (P1) 15
Periodical 2 (P2) 15
*Continuous Assessment (CA) 20
End Semester 50
*CA – Can be Quizzes, Assignment, Projects, and Reports.

Objectives and Outcomes


  • Understand Lean manufacturing principles and tools
  • Inculcate the concepts of value stream mapping
  • Familiarize lean implementation practices

Course Outcomes

  • CO1: Identify key requirements and concepts in lean manufacturing.
  • CO2: Initiate a continuous improvement change program in a manufacturing organization
  • CO3: Analyze and improve a manufacturing system by applying lean manufacturing tools
  • CO4: Build value stream map for improving the productivity
  • CO5: Improve productivity through lean practices

CO – PO Mapping

CO1 2 2 2
CO2 2 2 2 1 2 1 1 2 1
CO3 2 2 2 2 1 2 1 1 2 1 2
CO4 2 2 2 1 1 1 1 1 2 2 1 1
CO5 2 2 2 1 1 1 1 1 2 2 1 1

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