BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE, PILANI

WORK INTEGRATED LEARNING PROGRAMMES

Part A: Content Design
Course Title

Manufacturing Excellence

Course No(s)

ET ZC 417

Credit Units

Credit Model

1+1+2

Course Author
Version No
Date
Course Objectives

Dr. Naga Vamsi Krishna Jasti

Ver 1.2
16th July 2016

No
CO1

To enable you to design a globally competitive manufacturing organisation using manufacturing

excellence techniques

CO2

To develop the skills to implement manufacturing excellence principles in industry and manage
the change process to achieve continuous improvement of efficiency and productivity.

CO3

To enhance knowledge of participant to develop an integrated approach to address dynamic

organizational problems

Teaching methodology: Text Book(s)

T1

Besterfield D. H., et al., "Total Quality Management", Pearson Education, 1999.

T2

Pascal Dennis, Lean production simplified, Second Edition, Productivity Press, 2007

Reference Book(s) & other resources

R1

Voss C.A. "Manufacturing Strategy: Process and Content", Chapman & Hall, London, 1992.

R2

Nicholas J.M., "Competitive Manufacturing Management", Tata McGraw Hill Publishing

Company Limited, New Delhi, 2001.

R3

Mohanty R.P. and Deshmukh S.G., Advanced Operations Management, Pearson Education,
2003.

Modular Content Structure

1. Introduction Manufacturing Excellence

1.1. Overview of Manufacturing Excellence
1.1.1. Meaning of Excellence
1.1.2. Competing in World markets
1.1.3. Justification of Manufacturing Excellence
1.2. Characteristics of Manufacturing Excellence
1.2.1. Review of literature about the concept of manufacturing excellence.
1.2.2. Need of manufacturing excellence principles
1.3. Frameworks and competitive priority of organizations
1.3.1. Definition of framework and model in manufacturing excellence
1.3.2. Review of competitive priorities for manufacturing excellence.
2. Manufacturing Strategy
2.1. Introduction to Operations strategy,
2.2. Competitive priorities
2.3. Incorporating manufacturing perspective in corporate Strategy,
2.4. Missing the links in manufacturing strategy
. 3. Introduction to Lean Manufacturing
3.1. What is lean manufacturing?
3.2. What is difference between traditional and lean manufacturing
3.3. What is difference between JIT and lean manufacturing?
3.4. Application of lean manufacturing
3.5. Evaluation of production systems
3.6. Definition of lean manufacturing
3.7. Birth of lean manufacturing
3.8. Importance of lean manufacturing
3.9. Types of wastes
3.10. System and System thinking
4. Stability
4.1. What is stability?
4.2. What is Standardized Work?
4.3. What is role of stability and standardization in lean manufacturing?
4.4. Five pillars of lean manufacturing
4.5. Pillar: Stability and its tools
Visual Management
TPM
5. Standardized work
5.1.
Methods engineering versus lean thinking
5.2.
What do we have to manage?
5.3. Why standardized work?
5.4. The elements of standardized work
Production capacity chart
Standardized work combination table
Standardized work analysis chart
Job element sheets
Overall efficiency and individual efficiency
Common Layouts.
6. Just in Time Production
6.1. What is Just in Time (JIT)
6.2. Why JIT?
6.3. What is role of JIT in lean manufacturing?
6.4. Basic principles of JIT

Pull Production: types

Kanban
SMED
Production levelling
Heijunka box
Value stream mapping

7. Jidoka
7.1. What is Jidoka
7.2. Why Jidoka
7.3 Application of Jidoka
7.4. Jidoka
7.5. Poka yoke
Using Poka yoke
Three paths to Poka yoke
Poka yoke detection methods
Implementation steps
Case Study
8. Introduction to Total Quality Management (TQM)
8.1. Understanding quality
8.2. Difference between quality control and TQM
8.3. Requirements of TQM
8.4. Role of TQM in Manufacturing Excellence
8.5. Elements of TQM and its role
9. Benchmarking
9.1. What is qualitative and quantitative tools in TQM
9.2. What are the uses of qualitative and quantitative tools in TQM
9.3. Introduction and definitions of Benchmarking
9.4. Types of Benchmarking
9.5. Implementation steps and process
9.6. Advantages
9.7. Case Study: Benchmarking
9.8. Develop a problem on benchmarking
10. Failure Mode Effective Analysis
10.1. What is Failure Mode Effective Analysis (FMEA)
10.2. Uses of FMEA
10.3. Applications of FMEA
10.4. To learn the steps to developing FMEAs
10.5. To summarize the different types of FMEAs
10.6. To learn how to link the FMEA to other Black Belt tools
10.7. To perform an exercise on FMEA
10.8. Case Study: FMEA
11. Quality Function Deployment
11.1. What is Quality Functional Deployment (QFD)
11.2. Uses of QFD
11.3. Applications of QFD
11.4. QFD Team
11.5. Benefits of QFD
11.6. Voice of the Customer
11.7. House of Quality
11.8 Building a House of Quality: Case Study
11.9. QFD Process

12. Management Tools in TQM

12.1. Why, Why analysis
12.2. Force Field Analysis
12.3. Nominal Group Technique
12.4. Affinity diagram
12.5. Interrelationship Digraph (ID)
12.6. Tree diagram
12.7. Matrix diagram
12.8. Prioritization Matrices
12.9. Process Decision Program Chart (PDPC)
12.10.
Activity network diagram
13. Total Productive Maintenance
13.1. Evolution of maintenance
13.2. Difference between maintenance and TPM
13.3. Role of TPM in manufacturing excellence
13.4. Types of TPM
13.5. Overall equipment effectiveness
13.6. Numerical methods
Learning Outcomes:
No

Learning Outcomes

LO1

Able to adapt the continuous improvement program to achieve excellence in manufacturing

functions.

LO2

Able to apply lean manufacturing and quality system tools to enhance the performance factors of
production line.

LO3

Able to conduct, analyze and interpret experiments on process models

LO4

Able to identify opportunity, study, analyze and suggest possible improvement on the production
line

LO5

Able to apply critical lean manufacturing tools to enhance the existing production line.

Experiential learning components: Lab work:Operations Management Exercise: Push vs. Pull Production
Description
An exercise illustrates a fundamental concept in Operations Management and can be used to
reinforce key learning objectives in case studies and readings. In this single-player exercise, students
learn about two basic production triggering mechanisms used in production planning and inventory
control, Push and Pull. Students explore the differences between these common mechanisms in the
context of a computer manufacturing supply chain that feeds a retailer. In the process they learn about
implications for meeting demand and managing inventories and capacity utilization. The professor
can select corresponding assignment questions for each process. This exercise can be used for
courses in Operations Management for both MBA and undergraduate students. It is delivered entirely
online and requires one class meeting or less for students to run the exercise and discuss the results.

Learning objective:
1. To give students some intuition about production flow in a complex, multi-stage process, and how that
flow is affected by bottlenecks and production triggers;
2. To contrast the dynamic of Push, Pull, and mixed systems;
3. To explore the relations between batch size and set-up times in those systems.

Part B: Course Handout

Academic Term
Course Title
Course No
Lead Instructor

First Semester 2016-2017

Manufacturing Excellence
ET ZC417
Dr.Naga Vamsi Krishna Jasti

Contact Session 1
Sub Module Title: Introduction Manufacturing Excellence
Type

Content
Ref.

Topic Title

Pre
CH

1.1
1.2

Importance of manufacturing systems

What is manufacturing excellence

During 1.3
CH
1.4
1.5
1.6
1.7

Post
CH

1.8
1.9

Overview of Manufacturing Excellence

Meaning of Excellence
Competing in World markets
Justification of Manufacturing Excellence
Characteristics of Manufacturing Excellence
Review of literature about manufacturing excellence.
Need of manufacturing excellence principles
Competitive priorities for Manufacturing Excellence
Frameworks for Manufacturing Excellence
Case Study to show importance of manufacturing excellence
Analyze : Case Study
Quiz-1 questions provided by instructor

Study/HW
Resource
Reference
R4

R4

Quiz sheet
(to be
provided by
instructor)

Contact session 2
Sub Module Title: Manufacturing Strategy
Type

Content
Ref.

Topic Title

Study/HW
Resource
Reference

Pre
CH

2.1
2.2

During 2.3
CH
2.4
2.5

Post
CH

What is need of manufacturing strategy

Different types of manufacturing strategies and its
significance

2.6

Introduction to Operations strategy

Competitive priorities
Incorporating manufacturing perspective
Strategy,
Missing the links in manufacturing strategy

2.7

Assignment-1 given by instructor

in

R4
International
Journal
R4
corporate International
Journal

Contact session 3
Sub Module: Introduction to Lean Manufacturing
Type

Content
Ref.

Topic Title

Study/HW
Resource
Reference

Pre
CH

3.1
3.2

What is lean manufacturing

What is difference between traditional and lean
manufacturing
What is difference between JIT and lean manufacturing
Application of lean manufacturing

Online
Resource

3.3
3.4
During 3.5
CH
3.6
3.7
3.8
3.9
3.10

Post
CH

Difference between developing of lean manufacturing and

traditional production lines: Flexsim Software

3.11

Evaluation of production systems

Definition of lean manufacturing
Birth of lean manufacturing
Importance of lean manufacturing
Types of wastes
System and System thinking

T1 Chapter 9

Quiz sheet

Contact session 4
Sub-module Title: Stability and Standardized work
Type

Content
Ref.

Topic Title

Study/HW
Resource
Reference

Pre
CH

4.1
4.2
4.3

What is stability
What is Standardized work
What is role of stability and standardization in lean
manufacturing

Online
Resource

Five pillars of lean manufacturing

Pillar: Stability and its tools

T1 Chapter
15

During 4.4
CH
4.5

4.6

Post
CH

4.7

Visual Management
Pillar: Standardized work
Methods engineering versus lean thinking
What do we have to manage?
Why standardized work?
The elements of standardized work
Exercise on Standardization of work

Contact session 5
Sub-module Title: Standardized work
Type

Content
Ref.

Topic Title

Study/HW
Resource
Reference

Pre
CH

5.1
5.2

What is standard charts

Its application

Online
Resource

During 5.4
CH
5.5
5.6
5.7
5.8
5.9

Post
CH

Exercise on Standardized charts

5.10

Production capacity chart

Standardized work combination table
Standardized work analysis chart
Job element sheets
Overall efficiency and individual efficiency
Common Layouts.

T1 Chapter
15

Contact session 6
Sub-module Title: Just in Time Production
Type

Content
Ref.

Topic Title

Study/HW
Resource
Reference

Pre
CH

6.1
6.2
6.3

What is Just in Time (JIT)

Why JIT?
What is role of JIT in lean manufacturing

Online
Resource

Basic principles of JIT

Pull Production: types

T1 Chapter
15

During 6.4
CH

Post
CH

6.5

Kanban
SMED
Production levelling
Heijunka box

Exercise on Kanban and Pull Production

Contact session 7
Sub-module Title: Just in Time ProductionValue Steam Mapping
Type

Content
Ref.

Topic Title

Study/HW
Resource
Reference

Pre
CH

7.1
7.2
7.3

What is Value Stream Mapping (VSM)

What kind of information we are mapping in VSM
Application of VSM

Online
Resource

During 7.4
CH

Value stream mapping

Objectives
VSM Symbols
Steps in VSM
Case Study

T1 Chapter
15

Post
CH

Exercise on VSM

7.5

Contact session 8
Sub-module Title: Jidoka
Type

Content
Ref.

Topic Title

Study/HW
Resource
Reference

Pre
CH

8.1
8.2
8.3

What is Jidoka
Why Jidoka
Application of Jidoka

Online
Resource

During 8.4
CH

Jidoka
Poka yoke
Using Poka yoke
Three paths to Poka yoke
Poka yoke detection methods
Implementation steps
Case Study

T1 Chapter
15

Post
CH

Exercise on Poka yokeFlexsim

8.5

Contact session 9

Sub-module Title: Review

Type

Content
Ref.

Topic Title

Study/HW
Resource
Reference

Pre
CH

9.1

Review all classes

Previous
Classes

During 9.2
CH
9.3

Review: complete syllabus

Flexsim Assignments

Contact session 10
Sub-module Title: Introduction to Total Quality Management (TQM)
Type

Content
Ref.

Topic Title

Study/HW
Resource
Reference

Pre
CH

10.1
10.2
10.3

What is quality
What is Total quality management
What is difference between quality control and total quality
management

Online
Resource

During 10.4
CH
10.5
10.6
10.7
10.8

Post
CH

Importance of TQM: Flexsim software Assignment

10.9

Understanding quality
Difference between quality control and TQM
Requirements of TQM
Role of TQM in Manufacturing Excellence
Elements of TQM and its role

T1 Chapter
10

to be
provided by
instructor

Contact session 11
Sub-module Title: Benchmarking
Type

Content
Ref.

Topic Title

Study/HW
Resource
Reference

Pre
CH

11.1
11.2

What is qualitative and quantitative tools in TQM

What are the uses of qualitative and quantitative tools in
TQM
Introduction and definitions of Benchmarking

Online
Resource

Types of Benchmarking
Implementation steps and process
Advantages

T1 Chapter
11

11.3
During 11.4
CH
11.5
11.6
11.7

Case Study: Benchmarking

Post
CH

11.8

Develop a problem on benchmarking

Problems
identified in
the textbook

Contact session 12
Sub-module Title: Failure Mode Effective Analysis
Type

Content
Ref.

Topic Title

Study/HW
Resource
Reference

Pre
CH

12.1
12.2
12.3

What is Failure Mode Effective Analysis (FMEA)

Uses of FMEA
Applications of FMEA

Online
Resource
T1 Chapter
11

12.8

To learn the steps to developing FMEAs

To summarize the different types of FMEAs
To learn how to link the FMEA to Black Belt tools
To perform an exercise to actually perform
an FMEA
Case Study: FMEA

12.9

Develop a problem on FMEA

During 12.4
CH
12.5
12.6
12.7

Post
CH

Contact session 13
Sub-module Title: Quality Functional Deployment
Type

Content
Ref.

Topic Title

Study/HW
Resource
Reference

Pre
CH

13.1
13.2
13.3

What is Quality Functional Deployment (QFD)

Uses of QFD
Applications of QFD

Online
Resource

During 13.4
13.5
CH
13.6
13.7
13.8
13.9

Post
CH

Case study analysis

13.10

QFD Team
Benefits Of QFD
Voice Of The Customer
House Of Quality
Building A House Of Quality: Case Study
QFD Process

Contact session 14
Sub-module Title: Management Tools in TQM

T1 Chapter
11

Problems
identified in
the textbook

Type

Content
Ref.

Topic Title

Pre
CH

14.1
14.2

What is management tool

Online
How management tools are helpful to improve quality of the Resource
product
What are the management tools and list all

14.3
During 14.4
CH
14.5
14.6
14.7
14.8
14.9
14.10
14.11
14.12
14.13

Post
CH

Develop assignment to use all management tools

14.14

Why, Why analysis

Force Field Analysis
Nominal Group Technique
Affinity diagram
Interrelationship Digraph (ID)
Tree diagram
Matrix diagram
Prioritization Matrices
Process Decision Program Chart (PDPC)
Activity network diagram

Study/HW
Resource
Reference

T1 Chapter 7

Contact session 15
Sub-Module Title: Total Productive Maintenance
Type

Content
Ref.

Topic Title

Study/HW
Resource
Reference

Pre
CH

15.1
15.2

What is maintenance
How maintenance is useful to improve the productivity of

Online
Resource

the organization.
During 15.3
CH
15.4
15.5
15.6
15.7
15.8

Post
CH

Exercise problems on OEE

15.9

Evolution of maintenance
Difference between maintenance and TPM
Role of TPM in manufacturing excellence
Types of TPM and its role
Overall equipment effectiveness
Numerical method

Contact session 16
Sub-module Title: Review

T1 Chapter
13
International
Journal
Article

Type

Content
Ref.

Topic Title

Study/HW
Resource
Reference

Pre CH

16.1

Review all classes

Online
Resource

During CH

16.2
16.3

Review: complete syllabus

Flexsim Assignments

T1 Chapter
16

Evaluation Scheme:
Legend: EC = Evaluation Component; AN = After Noon Session; FN = Fore Noon Session
No
Name
Type
Duration Weight Day, Date, Session, Time
EC-1
Quiz-I/ Assignment-I Online
5%
September 1-10, 2016
Quiz-II
Online
5%
October 1-10, 2016
Quiz-III/
Online
5%
October 20-30, 2016
Assignment-II
10%
To be Announced
Lab Push-Pull
Online

System

lab

EC-2

Mid-Semester Test

EC-3

Comprehensive
Exam

Closed
Book
Open
Book

2 hours

30%

24/09/2016 (FN) 10 AM 12 Noon

3 hours

45%

05/11/2016 (FN) 9 AM- 12 Noon

Syllabus for Mid-Semester Test (Closed Book): Topics in Contact Hours : 1 to 8

Syllabus for Comprehensive Exam (Open Book): All topics (Session Nos. 1 to 16)
Important links and information:
Elearn portal: https://elearn.bits-pilani.ac.in
Students are expected to visit the Elearn portal on a regular basis and stay up to date with the latest
announcements and deadlines.
Contact sessions: Students should attend the online lectures as per the schedule provided on the Elearn
portal.
Evaluation Guidelines:
1. EC-1 consists of either two Assignments or three Quizzes. Students will attempt them through the
course pages on the Elearn portal. Announcements will be made on the portal, in a timely
manner.
2. For Closed Book tests: No books or reference material of any kind will be permitted.
3. For Open Book exams: Use of books and any printed / written reference material (filed or bound)
is permitted. However, loose sheets of paper will not be allowed. Use of calculators is permitted
in all exams. Laptops/Mobiles of any kind are not allowed. Exchange of any material is not
allowed.
4. If a student is unable to appear for the Regular Test/Exam due to genuine exigencies, the student
should follow the procedure to apply for the Make-Up Test/Exam which will be made available on
the Elearn portal. The Make-Up Test/Exam will be conducted only at selected exam centres on the
dates to be announced later.
It shall be the responsibility of the individual student to be regular in maintaining the self study schedule
as given in the course handout, attend the online lectures, and take all the prescribed evaluation
components such as Assignment/Quiz, Mid-Semester Test and Comprehensive Exam according to the
evaluation scheme provided in the handout.