Department of Engineering and Mathematics

Session: 2018-2019
Module: 55-704588
Lean Operations and Six Sigma
Module Leader: Dr. David Clegg
Assignment number/title: Assignment 2 Case Company
Academic contact for guidance: Dr. D Clegg

Maximum word count or number of pages: 2200

Percentage contribution to overall module mark: 60%

Deadline for submission: 15/01/2019 (15:00hrs)

Method and Location for Submission: Blackboard submission plus Turnitin

Insert Details of Other.

Deadline for return of feedback: 5/02/2019

Module learning outcomes to be assessed:

 Select, explain and reflect upon core lean principles and techniques.
 Demonstrate a working knowledge and application of lean principles and six sigma tools and
techniques to streamline selected businesses.
 Critically review recent developments in lean thinking, best practices and case studies.

References/recommended reading:

CAMP, Robert. B. (2013), Sustainable lean: the story of a cultural transformation. Boca Raton,
Fla.: CRC,

COX, I., GAUDARD, M. A., RAMSEY, P. J., STEPHENS, M. L., & WRIGHT, L. (2016).
Visual six sigma: making data analysis lean. John Wiley & Sons.

PANDE, Peter S., (2013), The Six Sigma Way, McGraw-Hill Education, 2nd Edition.

ROTHER, Mike and SHOOK John (2003), Learning to see: value stream mapping to create
value and eliminate muda. Brookline, Mass.: Lean Enterprise Institute, Edition Version 1.3.

WOMACK, J., P., JONES, D., T. and ROOS, D. (1990), The Machine that Changed the World,
Rawson Associates Scribner, New York

Please ensure that all sources of information used are referenced. For guidance see
http://libguides.shu.ac.uk/referencing
All assessments are subject to SHU's collusion and plaigiarism regulations. Please refer to:
https://students.shu.ac.uk/shuspacecontent/assessment/plagiarism

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Individual Assignment. This is an individual task, which requires the submission of a
written piece of work. To be wholly completed on an individual basis.

The customer's expectations

You have been employed as a consultant to implement Lean and 6 within a local
SME.
The case company will be provided separately.
You have just less than two months to consider all of the available material. After which
you are required to produce a written document detailing the manager's options.
(Resigning is not one of them!)

Task:

 Review the literature giving detailed examples of where within industry Lean and
6 has been applied, the strategies followed when implementing, the benefits
achieved and whether there are any lessons to be learned.
 Create a future state Value Stream Map.
 Propose approaches which can feasibly be considered when implementing lean
and 6 manufacturing principles within the case company. Stating where the
most benefit would be gained. While documenting your implementation plan are
there any tools and techniques which you would not implement?
 Taking the sawing process as a specific example discuss your approach to
ensuring that the machines are correctly set-up for each piece of bar that is cut.
Critically discuss how you would ensure that the measuring process for checking
the length of the sawn bar is appropriate.

Conditions of Assessment

 To be completed on a wholly individual basis.

 It is expected that some of the information which you consider necessary to
complete this assignment has been omitted and as such you will need to make a
number of assumptions. State all of the assumptions you have made in
completing this assignment.
 Your work should be appropriately and correctly referenced. If you are
unclear of how to reference your work please seek guidance from the
Learning Centre. APA is the standard recognised within the University.
 You are expected to write 2200 words.
 This assignment is worth 60% of the total assessment load.
 Late submission will result in a zero mark or capped mark being awarded in
common with standard university regulations.

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 Submission Date
Student name:
and Time
Student number: Marker:
Overall Mark:
Weighting Distinction (100 to Fail (49 to
Criterion: Merit (69 to 60%) Pass (59 to 50%) Mark:
: 70%) 0%)
Task 1 Creation of your own Many varied examples. A Examples applications given. One of two
Review the literature giving detailed table based on the table of applications from examples.
examples of where Lean has been analysis of the a published source.
applied, the strategies followed when 25% liturature including a
discussion of the
implementing, the benefits achieved
validity of the table.
and whether there are any lessons to
be learned.
H M L H M L H M L H M L
Task 2 Indicates where and Redesigns the process Minor mistakes but largely Does not
Create a future state Value Stream what changes are incorporating Lean tools appropriate symbols are understand
Map. required and and techniques. used. the concepts.
redesigns the
25% process
incorporating Lean
tools and
techniques.
H M L H M L H M L H M L
Task 3 Tools and Difficulty of implementing Schedule provided but Inappropriate
Propose approaches which can techniques which vs. benefit gained justification is lacking. Some schedule.
feasibly be considered when should not be together with an tools have been considered
implemented with appropriate schedule. together with where they
implementing lean and 6
appropriate could be applied.
manufacturing principles within the
25% justification in adition Implementation schedule,
case company. Stating where the to the difficulty of weightings given for each
most benefit would be gained. While implementing vs. activity.
documenting your implementation plan benefits and an
are there any tools and techniques appropriate
which you would not implement? schedule.

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 H M L H M L H M L H M L
Task 4 plus... Explicit examples from A plan is presented stating Some tools
Taking the sawing process as a Fully justified other businesses / how you would approach this stated.
specific example discuss your rational with industries stating how, problem.
approach to ensuring that the examples where and when the
presented. system you are proposing
machines are correctly set-up for each 25%
has been tools you are
piece of bar that is cut. Critically recommending have been
discuss how you would ensure that the implemented.
measuring process for checking the
length of the sawn bar is appropriate.
H M L H M L H M L H M L
Student Feedback: