Advanced Principles in Lean Manufacturing

Course Title: Advanced Principles in Lean Manufacturing

Course Code: PROD1024

EXAMINATION PAPER: ACADEMIC SESSION 2018/2019

Campus Medway

Faculty Engineering & Science

Level Seven

Exam Session January 2019

COURSE CODE PROD1024

COURSE TITLE Advanced Principles in Lean Manufacturing

Examination Type Unseen, closed book

Duration of examination 2 hours

List of appendices

Instructions to Candidates

Students will be required to achieve an overall grade of 50% to achieve a

pass.

Answer Question 1 in Section A and any two questions from Section B.

Marks are as shown

Page 2 of 8

Session: January 2019

Course Title: Advanced Principles in Lean Manufacturing

Course Code: PROD1024

SECTION A

Q1. (a) Why is Value Stream Mapping considered to be an important tool

in implementing lean manufacturing?

[8 marks]

(b) Refer to the case study data (over) and:

(ii) Draw the current state map for the Value Steam.

[12 marks]

(iii) Outline the eight major questions which should be asked,

and answered, when developing a future state map.

[16 marks]

(iv) Use your answer to Q1.(b)(ii) to develop and draw a Future

State Map, outlining the improvements made by

implementing a lean manufacturing strategy in this

organisation.

[14 marks]

Page 3 of 8

Session: January 2019

Course Title: Advanced Principles in Lean Manufacturing

Course Code: PROD1024

Case Study Data

Medway Motor Manufacturing Ltd produces automobile

components. One particular line produces assembled

components for petrol engines and diesel engines. The customer

is Colonel Motors Ltd.

Production Processes

 The manufacturing line process involves casting, surface

grinding, assembly, testing and packaging.

 The finished assemblies are staged and shipped to the

customer each day.

 50 stillages of raw material are delivered by the supplier, 2

times each month.

Colonel Motors’ Requirements

 1000 components per day. Of which:

 600 are for petrol engines

 400 are for diesel engines

 Components are to be shipped in trays of 25 components per

tray.

 The customer orders in multiples of trays.

 One daily shipment is sent to the customer by truck.

 Colonel Motors work 3 shifts per day, 20 working days per

month.

Medway Motor Manufacturing Work Time

 20 working days per month

 2 shifts of 8 hours per day, one ½ hour meal break, and two

12.5 minute coffee breaks per shift.

Production Control Department

 MRP system

 Customer emails demand forecast each week for the next 90

days

 Send monthly order for raw materials to supplier by fax

 Customer emails daily firm order

 Issues weekly schedule to casting, surface grinding,

assembly, testing and packaging.

 Issues daily shipping schedule to despatch.

Page 4 of 8

Session: January 2019

Course Title: Advanced Principles in Lean Manufacturing

Course Code: PROD1024

Process Information

The processes occur in the following sequence and each

workpiece passes through all the processes. Processes are

dedicated to this product family unless stated otherwise.

1. Casting

 Central resource, shared with other product families

 Cycle Time = 10 minutes, producing 30 components per

cycle

 Change Over Time = 25 minutes

 Inventory in front of the process = 15 days of raw material

 Uptime = 90%

 1 Operator

2. Surface Grinding

 Cycle Time = 44 seconds

 Change Over Time = 15 minutes

 Inventory in front of the process = 2400 petrol, 1600 diesel

 Uptime = 85%

 1 Operator

3. Assembly

 Cycle Time = 56 seconds

 Change Over Time = 10 minutes

 Inventory in front of the process = 3000 petrol, 2000 diesel

 Uptime = 100%

 2 Operators

4. Testing

 Cycle Time = 35 seconds

 Changeover Time = 12 minutes

 Inventory in front of process = 900 petrol, 600 diesel

 Uptime = 100%

 1 Operator

Page 5 of 8

Session: January 2019

Course Title: Advanced Principles in Lean Manufacturing

Course Code: PROD1024

5. Packaging

 Cycle Time = 2 minutes per tray

 Changeover Time = 30 seconds

 Inventory in front of process = 1800 petrol, 1200 diesel

 Uptime = 100%

 1 Operator

6. Shipping

 One shipment per day, typically of 40 trays

 Inventory before shipping = 240 trays of petrol assemblies,

160 trays of diesel assemblies

Page 6 of 8

Session: January 2019

Course Title: Advanced Principles in Lean Manufacturing

Course Code: PROD1024

SECTION B

Q2. (a) It is frequently said that the Lean Manufacturing philosophy is

underlined by five key principles. Name and briefly describe these

principles.

[7 marks]

(b) (i) Lean philosophy is driven by the identification and

eradication of waste. Identify the “seven deadly wastes”

first described by Taiichi Ohno, and briefly describe each

one

(ii) Several people have added to this original set of wastes.

Discuss some of the “New” wastes, and possible additions

yet to be made to the ever growing list.

[10 marks]

(c) Does Eliyahu Goldratt’s Theory of Constraints (TOC) conflict with

lean, or coincide with it? Outline the 5 stages of the TOC

ongoing improvement cycle, explaining the conflicts or synergies

of TOC and Lean Manufacturing as appropriate.

[8 marks]

Page 7 of 8

Session: January 2019

Course Title: Advanced Principles in Lean Manufacturing

Course Code: PROD1024

Q3. (a) Several companies struggling with a lean transformation have

found Hoshin, or Policy Deployment to be useful. What is meant by

the term “Policy Deployment”?

[5 marks]

(b) What are the five stages of Policy Deployment?

[5 marks]

(c) Why is “Setting the Direction” important for a company

undergoing a lean transformation?

[5 marks]

(d) What are the six stages in Developing a Strategy for a lean

transformation?

[6 marks]

(e) What is meant by the term “Time Pacing”? What are the main

advantages of Time Pacing in a lean transformation?

[4 marks]

Page 8 of 8

Session: January 2019

Course Title: Advanced Principles in Lean Manufacturing

Course Code: PROD1024

Q4. (a) Kaikaku, or “Kaizen events” are widely used to implement

process improvement in companies moving towards lean

production. Briefly explain how such events work, and what

results a company can expect from them.

[5 marks]

(b) Identify and briefly describe ten of the fourteen management

principles that Jeffrey K. Liker identifies as guiding Toyota on

their journey to becoming a world class manufacturing

organisation.

[20 marks]