Assessment Task(END OF MODULE EXAMINATION (GROUP

ASSIGNMENT ) 2018/19(for students)

Module Title LEAN OPERATION Module GTUM14EKM

Code
Assessment Group Assignment (4,000 words) Assessment 50%
title CW2: Production of a business No Component
policy for lean management in a
manufacturing or service system
Module Leader Dr. David King Tutor Dr.David King Boison / Ernest
Boison Ofori-Nyarko

LO’s Module learning outcomes covered by this test(from the Module descriptor)
1 1. Evaluate the current research and application of lean in manufacturing and the service industry.

2 2.
3 3.
4 4.
5 5. Apply lean techniques to the visual management and control of a manufacturing system.
6 6. Demonstrate the benefit to be gained from the consideration of ‘lean manufacturing’ throughout
the new p product development process and introduction.

Guidelines to the test

Hand in date 10/3/2019 Issue date
Background
A critical evaluation of the two (2) research papers is required to be able to answer the
questions appropriately. The two (2) research papers exemplify how lean operations has
been applied in the manufacturing and the service sectors and the benefits gained from its
implementation in areas of new product development.

Research Paper 1
Title: Reduction of Wastage Using Value Stream Mapping: Case Study
Abstract: The fundamental attention on lean production is the organised elimination of non-
value added activity and waste from the production process. The accomplishment of lean
principles and methods results in improved system and surrounding performance. Value
stream mapping is used to first map the current state used to identify sources of waste and
to identify lean tools to eliminate this waste. The future state map is then developed for a
system with lean tools applied to it. VSM is a pencil and paper visualization tool that shows
the flow of material and information as a product makes its way through the value stream.
VSM serves as a starting point to help management, engineers, suppliers, and customers
recognize waste and its sources. This paper demonstrates the implementation of lean
philosophy through layout modification.

Conclusion
We observed from this paper that VSM is an ideal tool to expose the waste and to identify
improvement areas. It helps the companies to reach their ultimate goal of sustainability and
profitable growth in the future. The case study on Value Stream Mapping shows that it is very
useful lean manufacturing tool for companies in being able to visually see how the entire
production process worked, as well as seeing how the individual processes worked. By

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being able to combine information and material on one map, this allowed us to see where
the big issues were in regards to lead time. We will able to then analyze the big issues and
make recommendations to remedy these problems. This study has provided important
insights into the current status of lean manufacturing implementation in the small industry in
Jaipur, as well as highlighted some associated issues. Firstly, the respondent companies’
involvement in lean manufacturing implementation has been discussed. The companies are
found to have not a good understanding of Lean Manufacturing. Only 37% companies are
aware about Lean Manufacturing which is a very small figure.

Research Paper 2
Title: STUDIES ON WASTE ELIMINATION STRATEGIES IN INDIAN AUTOMOTIVE
FIRMS USING TAKT TIME APPROACH
Abstract: Lean manufacturing is a performance-based strategy for maximizing customer
value by elimination of waste, while improving profitable growth of the organization. It is
viewed as a roadblock to customer satisfaction and a company's profitable growth. There is
an immense need for the manufacturing organizations to remain competitive and produce
high quality outputs not only at a national level but also at global level. Thus, numerous
companies have a major opportunity to reduce their costs and customer lead time and cycle
time through the application of Lean Manufacturing techniques. The present study has been
performed at Recliner Assembly Shop of an automobile manufacturing industry in North
India with an aim to develop and implement Lean Manufacturing Program. The systematic
procedure has been adopted to identify wastes, their reasons of occurrence and selection of
suitable methods adopted for their removal. The brainstorming sessions has been conducted
to chalk out causes and effects of different types of wastes. The expert’s views have been
collected to adopt the appropriate action leading to minimum cost, minimum effect on other
areas and maximum ease to eliminate the wastes. This study offers proven solutions for
implementing lean manufacturing in an enterprise environment, covering the engineering
and production aspects as well as the business culture concerns. It acts as a manual
providing the progressive steps to factory transformation to lean manufacturing.

Conclusion
From the results and discussion, the following conclusions are drawn:
1. Lean Manufacturing Tools have been successfully implemented in Automobile industry
with total average inventory reduction to Rs.411 lacs as compared to Rs.475 lacs initially.
2. Line balanced by doing TAKT time study by clubbing the operations with the existing
operations & line productivity is increased.
3. Lean manufacturing implementation has been shown to reduce the setup time by 29 %.
4. The breakdown is reduced by 4% and the absenteeism is reduced by 15%.
5. The cost of one-man power has been saved by Rs. 96000 annually.

NB: The two (2) research papers are attached to you to answer the questions below.
Students are to read these articles thoroughly before answering the questions below.

Questions.
1. Identify and discuss two (2) key problems that the two (2) research papers seeks to
address and justify their contributions to current research in lean manufacturing.
20 Marks
2. Discuss five (5) key findings of the two (2) papers and demonstrate whether these
findings are new to current literature, confirms or rejects existing literature?
20 Marks

3. Explain two (2) strengths and weaknesses of the methodology used by the two (2)
research papers and suggest one way to deal with the weaknesses in future

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 research .20 Marks

4. Appraise five (5) out of the seven (7) stages involved in developing a new product or
service for an organisation which intends to deploy lean manufacturing as a strategy
for competitive advantage. 10 Marks

5. Based on the findings and conclusions of the two (2) research papers, discuss five
(5) importance of lean manufacturing throughout a new product development cycle.
10 Marks
6. a) Critically assess the benefits of visual management system (VMS) in a new
product development. 10 Marks

b) State and explain five (5) key metrics or key performance indicators (KPIs) that you
will recommend in a manufacturing setup that intends to develop a new product using
lean technique. 10 Marks

How to pass this Test

In order to pass this test, you need to achieve a minimum grade of 40%:
 Answer all required questions
 ensure that you have fully met all the learning outcomes and tasks as detailed in this “Test”
brief

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