For the group - Zoomin

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For the group - Zoomin

Competitive Production Systems

Course Introduction and instructions

KPP202

Fall 2011 / HT11

Examiner and coordinator Anders Hellström

Version 2011-09-01

School of Innovation, Design and Engineering (IDT)

Product and Process Development


Objectives

The objective of the course is to give a general

understanding of the impact of competitive

production and logistics within industrial

operations.

The course will give an understanding of modern

production and logistics systems as well as

discuss the historic development and current

challenges for Swedish manufacturing industry.

p. 2 School of Innovation, Design and Engineering


Groups through out the course

The lecturer sets up groups of 6 (4-8) persons for the

entire course, for a god mix of experiences

If possible groups will be based on the known address

of students to facilitate meetings at MDH either in

Eskilstuna or Västerås.

p. 3

School of Innovation, Design and Engineering


Lecture 1 – 2011-09-01 (13.15-16.00) Anders Hellström

• Introduction to the course

– Registration

– Course Intro and Instructions, Course Home page

– Groups and participation

– Lean Methods

– Value Stream Mapping Example

– Handout of VSM group exercise INL2 part A 0,5 hp

– Handout of VSM group exercise INL2 part B 4,0 hp

– TEN1, supervised individual written examination at MDH

p. 4 School of Innovation, Design and Engineering


Group Exercise hand-out, VSM, INL2 part A, 0,5 ECTS

– Group task, make a first group Value Stream Map of 1 to 2 A4

pages, manual sketching and writing on readable level is OK:

• “clean clothes to student according to a students machine

wash process”, or

• another chosen process (e.g. a café)

– Presentation must be accepted as OK on both INL2 part A and

Part B for group members to achieve acceptance mark on the

total of INL2 (INL2 part A+part B)

p. 5 School of Innovation, Design and Engineering


Learning objectives

The student must be able to present her:

– understanding of production and logistics systems and the

effects of outsourcing

– understanding of TPS – Toyota Production System

– knowledge of a historical overview of industrial production

systems

– understanding of competitive and efficient production

– understanding of the key factors necessary for the follow up of a

modern production system

– understanding of different future production concepts

p. 6 School of Innovation, Design and Engineering


Examination

• INL2, 4.5 credits, group exercises, must be completed according to

schedule and before last lecture. If group member do not deliver according

to group plan an individual task may be specified by the teacher. At each

presentation all members of the group must participate and must be able

to show that he/she is fully updated on the full results of the group work.

INL2 is parted into INL2 part A 0,5 ECTS and INL2 part B 4,0 ECTS. Both

part A and B must be accepted to get an approval on INL2.

• TEN1, 3 credits, individual written examination according to MDH

schedule.

Major part of the examination TEN1 will be based on the textbook The

Toyota Way and the lectures by Antti Salonen. Other lectures give

examples for better understanding of the course material and will also be

used for parts of the TEN1 examination.

p. 7 • School of Innovation, Design and Engineering


Grades

• Exercises INL2A, INL2B and oral presentations – “ok” or “not ok"

• 3, 4 or 5 on TEN1

• 3, 4 or 5 on the course – set as same as examination TEN1 marks,

when all other results are “ok”

Literature

• Liker, J, The Toyota Way - ISBN 0-07-139231-9, chose latest version,

now available also in Swedish if preferred. Start your literature studies

early in beginning of the course so you can use the group work and

lectures for questions and discussions.

• Information made available through the web, some papers may also be

handed out at a lecture, but will thereafter only be available on the web.

Homepage of Competitive Production Systems, KPP202:

http://zoomin.idt.mdh.se/course/KPP202/index.asp

p. 8 • School of Innovation, Design and Engineering


Attendance and language

• The course is based on self studies of the textbook and active participation

in the lectures.

• Three certain advantages of the course are:

the guest lectures by people active in research and/or industry,

the mutual exchange of knowledge and feedback within group work, discussiona

and presentations, and

the factory visit to an internationally well established industry within the Volvo

Construction Equipment group

• Therefore we expect an attendance of at least 80% through the course.

The language in the course is English. In individual answers in TEN1 also

Swedish is accepted. In group work, group results and in discussions in

class room please pay respect to each other and use our common

language English.

p. 9 • School of Innovation, Design and Engineering


Instructions for the internal group work

At Lecture 1 the teachers will form the groups for the course and appoint the

group leaders.

Any changes of group members to be approved by teacher, teacher may

also include new students to a group.

The Group leader:

- has the right to delegate work to members within the group,

- has the right to appoint Group document administrator/

Secretary

- has the right to set schedules for meetings and other activities

- drives the group meetings

- keeps records over the active participation of each member in

the group work, problems with that to be discussed immediately

in group, and if not solved to contact the teacher to discuss

needed actions at next lecture

The Group document administrator/ Secretary:

- manage the group document archive

- ensure distribution of documents to and from the group

Each member: must perform his/her part of the group work.

Groups are recommended to define additional internal agreements.

p. 10 School of Innovation, Design and Engineering


References to The Toyota Way

• Basically, every chapter of The Toyota Way is of value to read!

Study it individually and preferably also in group discussions. All

chapters may occur at the Examination TEN1. Use the study

questions as a help for your studies.

• Part one gives an introduction to Toyota. Description of TTW theory

is found in Chapter 1, 3 and 4. Chapter 2 is of historical interest and

5 & 6 present some interesting case studies.

• Part two describes the actual 14 principles within TTW according to

Liker.

p. 11

School of Innovation, Design and Engineering


Exercise INL2 part B, alternatives 1 and 2

Exercise INL2B Alt 1: A Value stream mapping and

analysis of an industrial process, chose this alternative

if you have a good chance to cooperate with an

industry and to find a case to study there

Exercise INL2B Alt 2 : Production of a full application

instruction and implementation guide lines for a

chosen TPS methodology e.g. for value stream

mapping, 5S or other as agreed with the teacher

p. 12 School of Innovation, Design and Engineering


Exercise INL2B, alternative 1, page 1 of 2

• Value stream mapping and analysis of an

industrial process


a lean production method used to analyze the

flow of materials and information currently

required to bring a product or service to a

consumer

• You need to find your own case within industry or

other material handling enterprise , e.g. a

restaurant, for the exercise

p. 13 School of Innovation, Design and Engineering


Exercise INL2B, alternative 1, page 2 of 2

• A report/paper of maximum 10 pages describing;






The target product, product family, or service.

Drawing of current state value stream map, which is the current steps,

delays, and information flows required to deliver the target product or

service. This may be a production flow (raw materials to consumer) or a

design flow (concept to launch).

Waste and disturbance analysis

Proposal of a future state value stream map.

Implementation plan for the future state.

• Final oral presentation

p. 14 School of Innovation, Design and Engineering


Exercise INL2B, alternative 2, page 1 of 2

• Production of a full application instruction and

implementation guide lines for a chosen TPS methodology

e.g. for value stream analysis, 5S or other as agreed with

teacher. Based on TPS, describe the possibilities of the

method and its possible drawbacks if applied in a wrong

way.

• Work must include results from a test run from another

group using the set of documents by themselves. Own group

acting as silent and documenting observers at the test run.

An oral introduction of case and method is allowed. You are

recommended to Use the school MUX lab facilities.

p. 15 School of Innovation, Design and Engineering


Exercise INL2B, alternative 2, page 2 of 2

• A report/paper of maximum 10 pages including;




The produced full Application instruction and

implementation guide lines. The Guide material also

delivered to Anders in e-mail in format suited for course

web and later successful use by other course

participants.

A description of the test run and its results, results such

as found problems/opportunities and suggested changes.

Results from a group discussion based on each members

experience on how the Guide could have been, or could

be, used to improve a described segment of an industrial,

business or education process.

• Final oral presentation

p. 16 School of Innovation, Design and Engineering


Lecture 2 – 2011-09-06 (09.15-12.00)

• JIT-game. Just In Time production flow exercise

based on push respectively pull approach to show

the difference in the resulting flow

• 15 course members acting as the production staff

• All others participating in observation and analysis

• Sweeping of the shop floor…, all together!

PuMHa/Margareta Hammarström

Antti Salonen

p. 17 School of Innovation, Design and Engineering


Lecture 3 – 2011-09-08 (13.15-16.00)

• Lean implementation

• Group status INL2 part A and part B

• From Ford to Toyota

• The Toyota Way, study questions

Anders Hellström

p. 18 School of Innovation, Design and Engineering


Lecture 4 – 2011-09-13 (09.15-12.00)

• Competitive Production Systems – ongoing

research at Mälardalen University

• The need for flexibility and present trends

Mats Jackson

p. 19 School of Innovation, Design and Engineering


Lecture 5 – 2011-09-15 (13.15-16.00)

• Presentations from groups, INL2 part A

• TPS seen from Germany, P Grah

• Organizational Change, 5 steps

• Swedish Lean Initiative, Produktionslyftet,

implementation examples

Anders Hellström

p. 20 School of Innovation, Design and Engineering


Lecture 6 – 2011-09-20 (09.15-12.00)

• Maintenance introduction.

Impact on competitiveness.

Antti Salonen

p. 21 School of Innovation, Design and Engineering


Lecture 7 – 2011-09-22 (13.15-16.00)

Green Production Systems

• Green perspectives on competitive production

systems.

• The Next Great Leap Forward

• When Is Green Manufacturing Green

Karin Höckerdal

p. 22 School of Innovation, Design and Engineering


Lecture 8 – 2011-09-27 (09.15-12.00)

• Dependability

• Calculations

Antti Salonen

p. 23 School of Innovation, Design and Engineering


Lecture 9 – 2011-09-29 (ca 12.00.15-17.00 including

transportation, start at VCE industry gate 12.40 sharp, late

comers cannot be picked up!)

Timing details and Agenda may be changed, check web!

• Factory visit including factory tour at Volvo Eskilstuna

• Company information

• Volvo Production System, VPS

• Just-In-Time, JIT, at Volvo

• Process stability

• Factory tour

• Summing up

Marcus Bengtsson, Anders Hellström

p. 24 School of Innovation, Design and Engineering


Lecture 10 – 2011-10-04 (09.15-12.00)

• Understanding of competitive efficient production,

performance measurement

• Paradigm change from Push to Pull systems

• Goal oriented teams

Mohammed Salloum

p. 25 School of Innovation, Design and Engineering


Lecture 11 – 2011-10-06 (13.15-16.00)

• Competitive production systems from Haldex point

of view

• Lean driving at Haldex

Haldex is a provider of proprietary and innovative

solutions to the global vehicle industry, with focus

on products in vehicles that enhance safety,

environment and vehicle dynamics.

Monica Bellgran

p. 26 School of Innovation, Design and Engineering


Lecture 12 – 2011-10-11 (09.15-12.00)

• Groups status of INL 2 part B

• Lean implementation examples

• Questions and discussions

Anders Hellström

p. 27 School of Innovation, Design and Engineering


Lecture 13 – 2011-10-18 (09.15-12.00)

• Implementation of Lean and Change Management

• Group exercises

Mona Tjernberg

p. 28 School of Innovation, Design and Engineering


Lecture 14 – 2011-10-20 (13.15-16.00( if needed until 17.00))

• Project presentations, Exercise, INL2 part B

• Hand in of report on paper at 13.15

• 10 minutes presentation per group, all members

participates and can show own full understanding

of the group work

• 5 minutes of questions and feedback to each

group

Anders Hellström

p. 29 School of Innovation, Design and Engineering


Lecture 15 – 2011-10-25 (09.15-12.00)

• Research in Sweden within production and

production development

Christer Johansson

• Course summary

• Course evaluation

Anders Hellström

p. 30 School of Innovation, Design and Engineering


Lecture 16 – 2011-10-27 (13.15-16.00)

Overall Equipment Effectiveness

Antti Salonen

p. 31 School of Innovation, Design and Engineering


Examination opportunities, see web for updates!

Remember to apply in Students Portal for your

participation well in advance!

1 TEN1 2011-11-03 (14.10-18.30)

Eskilstuna and Västerås

2 TEN1 2012-01-19 (14.10-18.30)

Eskilstuna and Västerås

3 TEN1 2012- August, if any student still not approved

4 INL2 part A and part B only possible to examine

within the scheduled time of the course and only at

the scheduled time for presentation, also including

documentation at same time

p. 32 School of Innovation, Design and Engineering


Participating teachers

Monica Bellgran (PhD). Works as Director of Production

Technology and Systems at Haldex AB since 2007. Adj.

Professor in Innovative Production Development at MDH since

2006.

Marcus Bengtsson (PhD) senior researcher at Mälardalen

University. He received his PhD in Innovation & Design from

Mälardalen University in 2007. Marcus works part time at the

University, and part time as a Maintenance Engineer at Volvo CE

Components.

Mona Tjernberg is a Lecturer in Innovation Technology at the School of

Innovation, Design and Engineering at the Division of Innovation,

Entrepreneurship and Business Creation

p. 33

School of Innovation, Design and Engineering


Margareta Hammarström PuMHa Production Development. Works as

consultant within the area of production development.

Västersjövägen 59 , 35 91 Surahammar Mobil 070-399 80 25

http://www.pumha.com/ , margareta@pumha.com

References among others: AB Volvo Köpingsverken, ABB AB, ABB

Adda Italy, ABB Automation Products, ABB HV Switchgear in Sweden

and Italy, ABB Industrial System, ABB Management Consultants, ABB

Motors, ABB Production Development, ABB Signal, ABB Transportation

Management Germany, BOC Ohmeda, Flextronics International,

Anders Hellström MSc in Electronic Engineering at Linköping

University. Works as Head of Production, Design and Logistics division.

Lecturer in product development and quality assurance at MDH since

1998. Engineering and management experience from industrial product

development and production of safety, automotive and cash handling

systems within among other the Electrolux group.

p. 34

School of Innovation, Design and Engineering


Mats Jackson (PhD) is a professor in Innovative production at

the School of Innovation, Design and Engineering at Mälardalen

University. He is responsible for the research group within

product- and process development. He received his PhD

degrees from Linköping University. His research interests are

flexible and reconfigurable production systems. He has among

other been project leader of the Swedish national research

project Factory-in-a-Box.

Christer Johansson (PhD) is a professor at School of

Innovation, Design and Engineering at Mälardalen University, he

is also a Professor in Production Systems at Jönköping

University. He received his PhD degrees in 1982 at Linköping

University. His research has during the last fifteen years been

focused on development of manufacturing systems. The

research has been concentrated on principles, methods, and

tools for design, development, and evaluation of flexible

manufacturing.

p. 35

School of Innovation, Design and Engineering


Antti Salonen is a PhD in Product and process development at

Mälardalen University. His scope of research is Maintenance strategies

in the manufacturing industry.

Karin Höckerdal was enrolled as a doctoral student at Mälardalen

University, Innovation and Product Realization (IPR), in 2009. She has a

MSc in Industrial Engineering and Management from Linköping

University and her research focuses on integrating environmental

sustainability in production systems within the manufacturing industry.

Further, Karin is involved in the research project “Green Production

Systems”, and works close to the industrial partners of the project.

Mohammed Salloum is a controller at the Volvo CE aftermarket

division and an industrial PhD student at IPR in Eskilstuna. His

professional interests are management accounting & control systems

and the research dittos are consolidated around performance

management and measurement in relation to organizational change.

p. 36

School of Innovation, Design and Engineering


Group start up during Lesson 1:

Individually present to the group:

1. What do I want out of this course:

2. What gives me extra energy, how to get the best out of

cooperating with me:

For the group (Group leader direct the discussion):

1. Set meeting schedule for group meetings each week

2. Appoint Group document administrator/ Secretary and

make a members contacts list

3. Chose alternative 1 or 2 for the Exercise INL2B.

4. E-mail with header ”KPP202 Group/No/ INL2B chosen

alternative” 2011-09-06 to Anders. Include - contact list

and suggested industry/ suggested method.

p. 37

School of Innovation, Design and Engineering

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