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Teaching lean process design using a discovery approach

Abstract:

The lean laboratory exercises developed based on a physical simulation of a clock assembly called TIME WISE are discussed. The objectives of the program was to develop students' ability to apply lean design principles, develop students' ability to analyze data, and increase student understanding of fundamental process dynamics and variability. The laboratory exercises addressed manufacturing processes variabiilty, problem solving using a QI story format, process flow, supply chain management, and product customization. It was found that students who took to course with the added laboratory exercises expressed significantly more confidence in their ability to understand and apply lean ideas.