Launching Bradley’s first Lean manufacturing system design course

In a recent job search for industrial or manufacturing engineering positions, familiarity with Lean manufacturing consistently was ranked as either the first or second most important skill employers sought from prospective employees. Although it is simple to introduce what Lean manufacturing “is” in terms of philosophy, companies are now seeking engineers with real-world knowledge and practical work experience. Thanks to permission from the Illinois Manufacturing Extension Center (IMEC), the Department of Industrial & Manufacturing Engineering & Technology was able to conduct the first Lean manufacturing hands-on course in Bradley University’s history.

The course, taught by IMET Department Chair Dr. Joseph Chen, follows a number of stages that create an overview of Lean manufacturing usage in an actual company. First, an old job-shop type factory was constructed using training materials, and 14 students were assigned different job functions for 20 minutes, simulating the working environment in a factory. In this initial stage, accounting analysis with a focus on costs and revenues was conducted, and the company recorded a $762.50 loss. By providing students with these numbers, this stage demonstrated the downfall of a poorly designed manufacturing system, as a company in such financial circumstances would have little choice but to layoff workers or close the business.

In the second stage, Dr. Chen taught students how to identify “muda,” or the Japanese word for “waste.” Different Lean tools used to eliminate muda, such as standardization, 5S, setup reduction, Pull/Kanban systems, visual control, and point of usage storage, etc., were cited as solutions to identified waste.

After implementing Lean tools, students eliminated unnecessary work stations and created a U-shaped facility layout that increases efficiency and decreases waste. They simulated production once again using their new manufacturing system design and recalculated costs. In the end, the accounting system showed a profit of $467.50—quite a dramatic change from the previous loss of $762.50. Within only six hours, students were able to relieve a company of a desperate situation and turn it into a profitable factory. Thus, through a hands-on study of the manufacturing process, students truly recognized the power of Lean manufacturing.

Though the workshop is over, student exposure to Lean manufacturing principles certainly will not end with this course. Throughout the semester, they will have the opportunity to become involved in industrial projects to implement Lean principles in a real-world project. The department is currently planning future Lean courses and project opportunities for students.