Department of Engineering and Mathematics

Session: 2021-2022
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: 2000 per student

Percentage contribution to overall module mark: 50%

Deadline for submission: 10/01/2022 (15:00hrs)

Method and Location for Submission: Blackboard submission plus Turnitin

Insert Details of Other.

Deadline for return of feedback: 31/01/2022

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: APA

Camp, R. B. (2013). Sustainable lean: the story of a cultural transformation. CRC

Press.

Cox, I., Gaudard, M. A., & Stephens, M. L. (2016). Visual six sigma: making data
analysis lean. John Wiley & Sons.

Pande, P., Neuman, R. and Cavanagh, R., (2000). The Six Sigma Way. New York:
McGraw-Hill.

Rother, M. and Shook, J., (2003). Learning To See. Kbh.: Dansk Industri.

Roos, D., Womack, J. and Jones, D., (2014). The Machine That Changed The World:
Free Press.

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 plagiarism regulations. Please refer to:
https://students.shu.ac.uk/shuspacecontent/assessment/plagiarism

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2
Sections 2 and 3 of this assignment are to be completed as a group of three.
One member of the group will individually complete Task 1, and as a group complete
Tasks 2 and 3.
The second member of the group will individually complete Task 4, and as a group
complete Tasks 2 and 3.
The third member of the group will individually complete Task 5, and as a group
complete Tasks 2 and 3.

Task 1 Person A
Task 2 Person A, B & C
Task 3 Person A, B & C
Task 4 Person B
Task 5 Person C

The Tasks

You have been employed as a consultant to implement Lean and 6s within a local
SME.
The case company details will be provided separately.
You have just less than two months to consider all the available material. After which
you are required to produce a written document detailing the options the manager
should consider.

Task:

1) Critical review of the literature giving detailed examples of where within industry
Lean and 6s have been applied, the strategies followed when implementing, the
benefits achieved and whether there are any lessons to be learned.
This is an individual task.

2) Create current and future state Value Stream Maps (VSM).

To be completed in pairs.

3) Relating back to your future state VSM propose approaches which can feasibly
be considered when implementing lean and 6s 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; either immediately, within the year or indeed at any
time?
To be completed in pairs.

4) Being able to sustain the improvements implemented through Lean-6sigma

initiatives is challenging. Discuss, with reference to the literature, how you would
ensure that any changes implemented within the case company are sustainable
in the long term.
This is an individual task.

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5) By the time you read this assignment the 2021 United Nations Climate Change
Conference, also known as COP26 will have been and gone and this year’s
University’s Big Read 2021 will have been released; How to Save Our Planet:
the Facts by Professor Mark Maslin, an important book for anyone who wants to
learn more about the climate emergency and what action we can take.
With the increasing awareness of needing to reduce emissions, you are required
to critically analyse and discuss, with reference to the literature, whether all of
the tools available to a practitioner of Lean 6 Sigma remain valid or whether
some tools should be avoided or replaced. In essence, is Lean 6 sigma
compatible with and still relevant with being Green? In light of your findings, is
there any part of the case study’s business which should be changed?

If you wish to read the book; How to Save Our Planet: the Facts by Professor
Mark Maslin, you may collect one, free of charge, from outside 4129, Sheaf
Building.
This is an individual task.

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Conditions of Assessment

 This assignment is worth 50% of the total assessment load.

 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 using the APA
standard as recognised within the University. If you are unclear of how to
reference your work, please seek guidance from the Study Skills Centre.
 For sections 1, 4 and 5 you are EACH expected to write 1500 words ±10%
excluding the list of references.
 As a group you may also write up to 1500 words ±10% excluding the list of
references for section 3.
 Late submission will result in a zero or capped mark being awarded in common
with standard university regulations.
 On the front-page state which student has completed each part.
 I will assume that all parties will have contributed equally to the joint submission
unless you notify us, in writing using the Group contribution form, BEFORE the
submission date.
 Ideally, you should select a partner from within your tutorial group.
 You do not need to tell me who your partner is before you submit. However, if
you require assistance in forming a pair then please let me know ASAP so that a
list of students whom would like assistance in finding a partner can be collated.

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Student A’s Name: Student B’s Name: Student C’s Name:
Student A’s Number: Student B’s Number: Student C’s Number: Overall Mark:

Distinction Merit Pass Fail

Criterion and Weighting   Mark:
(100 to 70%) (69 to 60%) (59 to 50%) (49 to 0%)
Task 1: 50%, individual Creation of your own table based on Only one or two examples
analysis of the literature, including a with little analysis.
Critical discussion of the literature critical discussion of the validity of The student only
Critical discussion of
giving detailed examples of where the table. evidences an
many varied examples Limited discussion of
Lean has been applied, the Excellent knowledge and understanding of small
understanding evidenced by some
which may include a example applications
subset of the taught
   
strategies followed when table of applications from given but lacks detail.
implementing, the benefits achieved clear independent insight and concepts and techniques;
a published source.
and whether there are any lessons critical awareness of relevant fails to make sufficient
to be learned. concepts some of which are at the links between known
forefront of the discipline concepts and facts
  ED HD MD LD HM MM LM HP MP LP BF MF LF VLF Zero  
Task 2: 25%, pair Original and redesigned
Indicates what and where changes VSMs incorporating
Some mistakes but Little evidence of
are required. Redesigns the Lean tools and
Create current and future state process incorporating appropriate techniques with very
largely appropriate understanding the    
Value Stream Maps. symbols are used. concepts.
Lean tools and techniques. minor errors or
omissions.
  ED HD MD LD HM MM LM HP MP LP BF MF LF VLF Zero  

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Task 3: 25%, pair Schedule provided
An appropriate
Propose approaches which can but justification is
Critical discussion of which tools schedule is presented
feasibly be considered when lacking. Some tools
and techniques should and but with little
implementing lean and 6s have been
should not be implemented with discussion of the
manufacturing principles within considered together
appropriate justification for both. difficulties of Inappropriate schedule
the case company. Stating where The difficulty of implementing. implementing and the
with where they
or tools and techniques.
   
the most benefit would be gained. could be applied.
The benefits of implementing and benefits likely to be
While documenting your Implementation
an appropriate schedule should gained presented with
implementation plan are there any schedule, weightings
be included. appropriate reasoning
tools and techniques which you given for each
and references.
would not implement? activity.
  ED HD MD LD HM MM LM HP MP LP BF MF LF VLF Zero  
Task 4: 50%, individual Some tools /
As merit, plus... suggestions are stated
Fully justified rational with Explicit examples from but with little reference
A plan is presented
Maintaining improvements made examples presented. Excellent other businesses / to the literature.
stating how you
is challenging. Discuss, with knowledge and understanding industries stating how, The student only evidences
would approach the
reference to the literature, how evidenced by some clear where and when the
challenge of
an understanding of small    
you would ensure that any independent insight and critical system you are subset of the taught
maintaining any
changes implemented are awareness of relevant concepts proposing has been concepts and techniques;
improvements made.
sustainable in the long term. some of which are at the forefront implemented. fails to make sufficient links
of the discipline between known concepts
and facts
  ED HD MD LD HM MM LM HP MP LP BF MF LF VLF Zero  
Task 5: 50%, individual As merit, plus... Some tools /
Fully justified rational with suggestions are stated
Some examples from but with little reference
Critically analyse and discuss, examples presented. Propose Explicit examples from
the literature, to the literature.
with reference to the literature, ways in which the tools need to the literature,
businesses / The student only evidences
whether all of the tools available be adapted. Excellent knowledge businesses / industries
and understanding evidenced by stating how, which of
industries stating an understanding of small    
to a practitioner of Lean 6 Sigma how, which of the subset of the taught
remain valid or whether some some clear independent insight the tools remain
tools remain relevant concepts and techniques;
tools should be avoided or and critical awareness of relevant relevant and why.
and why fails to make sufficient links
replaced. concepts some of which are at the between known concepts
forefront of the discipline and facts
  ED HD MD LD HM MM LM HP MP LP BF MF LF VLF Zero  

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 Level 7: Generic grade descriptor: relationship of grades of achievement to percentage mark ranges and categorical grades (CG)
Class Category General Characteristics
Exceptional breadth and depth of knowledge and understanding evidenced by own independent insight and critical awareness of relevant literature and
concepts at the forefront of the discipline; evidence of extensive and appropriate independent inquiry operating with advanced concepts, methods and
techniques to solve problems in unfamiliar contexts; Cogent arguments and explanations are consistently provided using a range of media demonstrating an
Distinction Exceptional Distinction
ability to communicate effectively in a variety of formats using a sophisticated level of the English language in an eloquent and professional manner to both
(Exceptional)
technical and non-technical audiences; a sustained academic approach to all aspects of the tasks is evidenced; academic work extends boundaries of the
disciplines and is beyond expectation of the level and may achieve publishable or commercial standard.
Excellent knowledge and understanding evidenced by some clear independent insight and critical awareness of relevant concepts some of which are at the
High Distinction
forefront of the discipline; evidence of appropriate independent inquiry operating with core concepts, methods and techniques to solve complex problems
Distinction Mid Distinction in mostly familiar contexts; Arguments and explanations are provided that is well-supported by the literature and in some cases uses a range of media
(Excellent) demonstrating an ability to communicate effectively in a limited number of formats using own style that is suited to both technical and non-technical
audiences; a sustained academic approach to most aspects of the tasks is evidenced; one or more aspects of the academic work is beyond the prescribed
Low Distinction
range and evidences a competent understanding of all of the relevant taught content.
High Merit Very good knowledge and understanding is evidenced as the student is typically able to independently relate taught facts/concepts together some of
which are at the forefront of the discipline; evidence of some competent independent inquiry operating with core concepts, methods and techniques to
Merit solve familiar problems; Arguments and explanations are provided that are typically supported by the literature and in some cases may challenge some
Mid Merit
(Good) received wisdoms; competently uses all taught media and communication methods to communicate effectively in a familiar settings; an academically
rigorous approach applied to some aspects of the tasks is evidenced; some beyond the prescribed range, may rely on set sources to advance work/direct
Low Merit
arguments; demonstrates autonomy in approach to learning.
High Pass Satisfactory knowledge and understanding of the area of study balanced towards the descriptive rather than critical or analytical and mostly confined to
concepts that are not at the forefront of the discipline; evidence of some independent reading and research to advance work and inform arguments and
Pass Mid Pass approaches; Arguments and explanations are limited in range and depth although some are adequately supported by the literature albeit descriptively
(Sufficient) rather than critically; competently uses at least one taught media and communication method to communicate appropriately in familiar settings; although
the approach applied to some aspects of the tasks may lack academic rigour, there are some clear areas of competence within the prescribed range. Relies
Low Pass
on set sources to advance work/direct arguments and communicated in a way which shows clarity but structure may not always be coherent.
Borderline Fail Knowledge and understanding is insufficient as the student only evidences an understanding of small subset of the taught concepts and techniques; fails
to make sufficient links between known concepts and facts to adequately solve relevant aspects of the brief/problem; little ability to independently select
Mid Fail and evaluate reading/research with almost total reliance on set sources and unsubstantiated arguments/methods; communication/presentation may be
FAIL
competent in places but fails to demonstrate structure, clarity and/or focus; inability to adequately define problems and make reasoned judgements; the
(Insufficient)
Low Fail general approach to tasks lacks rigor and competence.

Knowledge and understanding is highly insufficient as the student is unable to evidence any meaningful understanding of taught concepts or methods;
FAIL very limited evidence of reading and research to advance work; inadequate technical and practical skills as the student is unable to use and apply such
Very Low Fail
(Incompetent) skills to address problems or make judgements; limited or lack of understanding of the boundaries of the discipline and does not question received
wisdom; approach to learning lacks autonomy and approach to tasks is not sustained; inability to communicate coherently.
ZERO
Zero Work not submitted, work of no merit, penalty in some misconduct cases.

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 Group contribution form
55-704588, LEAN OPERATIONS AND SIX SIGMA

Please complete this form individually.

Every group member is required to complete a contribution form before the group assignment
deadline. If you choose not to complete a form, you will forfeit your opportunity to provide
insight into the contributions of your group (including your own contribution) at the stage when
the forms are considered.

Your contribution forms will be considered carefully by the lecturer and the module’s
moderator. Your own indication of your own contribution will be taken into account along with
the forms from your peers. As well as this contribution form, contributions may also be
determined through the following method: Interview. This second method will be used if there
is not a clear enough picture from the contribution sheets alone.

You ideally all contributed the same. Marks for the assignment will be adjusted according to the
departmental approach if there is clear evidence that at least one student has not contributed as
much as the rest of the group. If there is clear evidence, the contribution forms will be used to
determine how much less a group member has contributed and their group mark will be
adjusted by a standard amount. When filling in the contribution form, take into account the
size / complexity of the tasks carried out by each group member.

If someone has done more work than the others, marks will not be increased to reflect this.
However, group size and the number of students contributing to an assessment will be taken
into account. Expectations will be adjusted based on this.

Note that contribution is more than attending meetings. Each group member needed to
contribute to the work that was produced. It is possible for someone to gain a mark of 0 even if
they have attended meetings and classes if it is clear they haven’t contributed to the work
submitted by the team.

If you have any concerns about how the marks are awarded, please talk to the lecturer. Note
that, like all marks, marks are provisional until they have been through an assessment board.
Note that we cannot disclose how we have dealt with the marks of other students as it’s
confidential to each student.

Contributions

Q1) How many people were in your group (including yourself)? ______

Q2) Who were the members of your group?

Your name

Other group members Member A

Member B

Member C

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Q3) Do you think everyone in your group should obtain the same mark?
Yes / No

Evidence:

Q4) Briefly explain why (you can refer to the second measure of contribution if appropriate):

Q5) Select the response that best describes the contribution of each group member:

Equal to or About 25% About 50% About 75% No

higher than less than the less than the less than the contribution
the average average average average or no useful
contribution in contribution contribution contribution contribution
the group in the group in the group in the group

Yourself

Member A

Member B

Member C

Further evidence

Q6) Consider the contribution that you and the other group members made to the group work.
Give each person in your group (including yourself) a score for each of the criteria below. You
should award a score of 0 for no contribution, 1 for a contribution below the average, 2 for a
contribution which was about the same as other group members and 3 for a group contribution
which was above the average.

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Criteria Yourself Member A Member B Member C Member D

***Include 4-6 criteria specific

to your assessment - e.g
activities such as researching
the topic, calculations,
drawings, writing code,
writing the report, etc**

***Include 4-6 criteria specific

to your assessment***

***Include 4-6 criteria specific

to your assessment***

***Include 4-6 criteria specific

to your assessment***

***Include 4-6 criteria specific

to your assessment***

***Include 4-6 criteria specific

to your assessment***

Useful contributions to
meetings and discussions

Organising the work

Providing ideas and

influencing decisions

Providing support and

encouragement

Preparing the final

assessment output

Proofreading / checking

Doing a fair share of the work

TOTAL SCORE

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