ENMA
6040: Lean Systems
Project
Deliverables
Industry-sponsored
student team projects form the core learning activity for this course. As a team executes their project, they will
hand in a sequence of project deliverables on the due days specified by the
course schedule. This web site provides
information on how to prepare and submit project deliverables.
·
Project
Deliverables Overview
The
following deliverables will be completed by each project team. Details on how to complete each deliverable
are provided in a following section.
2. Process flow diagram
3. Waste identification
4. 5-S assessment
5. Value stream map
6. Visual control –
standardization
7. Process flow simulation
8. Final presentation
9. Supplemental materials
1.
Project overview
Your
instructor will have provided you with a brief summary of your project and
contact information for your project sponsor.
For this deliverable, the team will add the next level of detail to this
description, including a clear, concise, complete statement of the specific
problem to be solved for the sponsor.
The overview should also include information about the sponsor’s
business, products, and markets, but should not contain any reference to the
name of the sponsor’s organization.
2.
Process flow diagram
Using
the nomenclature provided in the course lecture on process flow diagrams, the
team will prepare a preliminary process flow diagram for their project’s
process. As the first deliverable for
the team’s project, the diagram may not include all process details, so the
team should consider this a living document and add details to the flow chart
as the team learns more about their process over the course of the
semester. That being said, it is
essential that the flow chart clearly delineate the scope of the project, i.e.,
which elements of the overall process are “inside” of the team’s project and which
elements are outside of the boundaries of the project and will not be included
in the process analysis. The team is
encouraged to construct the flow chart using either major step or swim
lanes. This deliverable should be
prepared as Microsoft PowerPoint document, but the actual process flow chart(s)
should be prepared using Microsoft Visio, and should be submitted as
supplemental materials (see Deliverable #8).
The means whereby students can download a free student version of Visio
is described in the course lecture on downloading Visio. As outlined in the example provided in the
process flow diagram course lecture, the diagram should be accompanied by a
glossary of terms defining any terms that someone unfamiliar with the process
might not understand.
3.
Waste identification
For
this deliverable, the team will walk through the process and note sources of
waste using to the waste categories described in the course lecture on sources
of waste. The team should use their
process flow diagram from Deliverable #1 as a map for conducting their waste
identification walkthrough, with waste identification being done at each step
in the process flow diagram. A template
has been prepared that can be used to document waste found at each process
step. The team should then make a copy
of their Visio process flow diagram from Deliverable #1 and transfer
information on the most critical sources of waste directly onto this second
process flow diagram. (This second
process flow diagram should be prepared using Visio, and should be submitted as
supplemental material.) In order to
complete this deliverable in a quality manner within the time allotted, the
team may choose to focus on just one critical segment of their process, rather
than the entire process. Please note
that the team is not expected to initiate correction of the identified sources
of waste – that will be left to the project sponsor to pursue as they see fit.
The deliverable presented by the team in class can be based on the PowerPoint
presentation of Deliverable #1, with sources of waste added to the process flow
diagram, and additional slides added to provide detail on the primary sources
of waste that have been identified.
4.
5-S assessment
For
this deliverable, the team will perform an assessment of the degree to which
5-S activities are being applied in the process they are analyzing. The team will use the template provided to
assess the level of 5-S activities currently in the process. Upon completion of the assessment, the team
will recommend one or more activities that can move the process to the next
level of 5-S. As with the waste
identification deliverable, the team will not be expected to conduct 5-S
activities – that will also be left to the sponsor’s discretion. Rather, the team will focus on assessing the
level of current 5-S activities and recommend next actions. As with the waste identification deliverable,
the team will note these recommendations directly onto another copy of the
process flow diagram of Deliverable #1 (also submitted as supplemental
material). In order to complete this
deliverable in a quality manner within the time allotted, the team may choose
to focus on just one critical segment of their process, rather than the entire
process. The deliverable presented by the
team can be based on the PowerPoint presentation of Deliverable #1, with 5-S
recommendations added to the process flow diagram, and additional slides added
to provide detail on the recommendations.
5.
Value stream map
Using the nomenclature provided
in the value stream mapping lecture, the team will use their process flow
diagram as a basis for preparing a value stream map for their process. By this time, the team should have a good
grasp of their process, so the value stream map should form a complete and
accurate description of their process.
The value stream map should include a clear identification of
value-adding steps and non-value-adding steps, and estimations of times
associated with each step. Given the time
available to complete this deliverable, only rough estimations of step times
may be available at this point, and as with previous deliverables, the team may
need to limit the scope of the value stream map to complete this deliverable in
schedule. The value stream map should be
created as a Visio document and submitted as supplemental material. This deliverable should be prepared as a
PowerPoint presentation.
6.
Visual control –
standardization
Based
on the information provided in the visual controls lecture, the team will
prepare visual controls for their process.
Typically, these visual controls consist of graphic signage describing
standardized work procedures for critical steps in the process. The team will identify a segment of their
process that could benefit from the development and/or documentation of work
standards, and will design the needed visual controls. The team will note on a copy of their process
flow diagram from Deliverable #1 where the visual controls are to be
added. This diagram and the visual
control designs should be submitted as supplemental materials. The team’s visual control design and
recommendations should be described in their PowerPoint presentation for this
deliverable. Again, the scope of this
deliverable should be limited appropriately.
1.
Process flow simulation
Based
on the Arena simulation software tutorials for this course, the team will use
Arena simulation software to simulate a critical segment of their process. The process flow diagram of Deliverable #1
and the value stream map of Deliverable #4 will provide the basic structure and
timing for the simulation. The purpose
of the simulation is to identify major flow bottlenecks in the process and
points at which WIP accumulates in the process.
The actual Arena .doe model should be submitted as supplemental materials,
and the structure of the model and results of the bottleneck and WIP analysis
should be summarized in the PowerPoint presentation for this deliverable. Again, the scope of this deliverable should
be limited appropriately.
2.
Final presentation
Teams
will prepare a final presentation containing their findings associated with the
preceding project deliverables, and will recommend specific next actions for
their project sponsor based on these findings.
It is anticipated that each of the preceding deliverables will be
integrated into the PowerPoint final presentation, with the presentation
concluding with next step recommendations.
Project sponsors and interested parties are strongly encouraged to
attend the final presentation.
Deliverables should contain no references
to the name of the project sponsor, and should not contain any information that
would allow the sponsor company to be identified, unless specifically requested
by the sponsor.
3.
Supplemental materials (description under construction)
In
the process of completing the preceding project deliverables, teams will
generate a variety of support materials that will not appear in the
presentations that the teams will be giving in class for each project
deliverable. These materials should be
put in the supplemental materials D2L folder for the project. The primary purpose of collecting
supplemental materials is to assist future project teams that may pick up the
project. The basic rule of thumb is
this: If YOU were inheriting this
project from last semester’s project team, what would YOU find valuable for
your project? All supplemental materials
should also be delivered to your team sponsor.