Professor
John RomagnoliLearning objectives
KNOWLEDGE AND ABILITY TO UNDERSTAND: At the end of the course, the student must have acquired the main knowledge relating to the concepts of quality, maintenance, and the lean production philosophy for the design and management of production systems.
ABILITY TO APPLY KNOWLEDGE AND UNDERSTANDING: The student will be able to design a production system according to the principles of maintenance, quality and lean production, defining the most suitable management policies in relation to the specific production system, production planning activities and control of the supply logistics of the production lines.
JUDGMENT ABILITY: The student must be able to critically evaluate a production system; that is, design, choose and implement a lean system that ensures and controls quality and plan the respective preventive and predictive maintenance activities, as well as adequately manage fault maintenance.
COMMUNICATION SKILLS: The student will have to acquire the specific vocabulary related to maintenance and quality management and lean methodology. It is expected that, at the end of the course, the student will be able to transmit, orally and in writing, also through the resolution of numerical problems, the main contents of the course.
LEARNING SKILLS: The student who has attended the course will be able to deepen his/her knowledge in the field of design of lean production systems that ensure and control quality, as well as the management of their maintenance, including the design and management of supply logistics of assembly lines; design and management of quality assurance and control systems and visual management.
Expected learning outcomes
KNOWLEDGE AND ABILITY TO UNDERSTAND: At the end of the course, the student must have acquired the main knowledge relating to the concepts of quality, maintenance, and the lean production philosophy for the design and management of production systems.
ABILITY TO APPLY KNOWLEDGE AND UNDERSTANDING: The student will be able to design a production system according to the principles of maintenance, quality and lean production, defining the most suitable management policies in relation to the specific production system, production planning activities and control of the supply logistics of the production lines.
JUDGMENT ABILITY: The student must be able to critically evaluate a production system; that is, design, choose and implement a lean system that ensures and controls quality and plan the respective preventive and predictive maintenance activities, as well as adequately manage fault maintenance.
COMMUNICATION SKILLS: The student will have to acquire the specific vocabulary related to maintenance and quality management and lean methodology. It is expected that, at the end of the course, the student will be able to transmit, orally and in writing, also through the resolution of numerical problems, the main contents of the course.
LEARNING SKILLS: The student who has attended the course will be able to deepen his/her knowledge in the field of design of lean production systems that ensure and control quality, as well as the management of their maintenance, including the design and management of supply logistics of assembly lines; design and management of quality assurance and control systems and visual management.
Course content
1. INTRODUCTION TO LEAN MANUFACTURING
2. LOSS IDENTIFICATION AND VALUE STREAM MAPPING
3. THE 5S AND SMED (SINGLE-MINUTE EXCHANGE OF DIE) METHODOLOGIES
4. CREATE CONTINUOUS FLOW
5. MANAGE THE FLOW OF MATERIALS
6. PUSH, PULL AND HYBRID SYSTEMS
7. INTRODUCTION TO QUALITY MANAGEMENT
8. QUALITY MANAGEMENT SYSTEMS
9. STATISTICAL METHODS OF QUALITY MANAGEMENT
10. THE ACCEPTANCE TEST
11. INTRODUCTION, MAINTENANCE POLICIES AND METHODS
12. MAINTENANCE MODELS
13. SPARE PARTS MANAGEMENT
14. THE MAINTENANCE INFORMATION SYSTEM
Prerequisites
No mandatory prerequisites. Attendance and passing of courses related to production systems design, production management and statistics are desirable.
Bibliography
The teacher will upload the teaching material needed for the course in the form of slides onto the MS TEAMS platform.
Possible texts for personal study are:
– Womack, Jones, Roos, (1990) The Machine That Changed the World: The Story of Lean Production, Free Press
– Womack, Jones, (1996) Lean Thinking, Productivity Press
– Harris, Rother, (2001) Creating Continuous Flow: An Action Guide for Managers, Engineers & Production Associates, Productivity Press
– Harris, Harris, Wilson (2003) Making Materials Flow: A Lean Material-Handling Guide for Operations, Production-Control, and Engineering Professionals, Lean Enterprise Institute
– Manzini, Regattieri, (2007) Maintenance of production systems, Esculapio publisher
Teaching methods and tools
The course has a weight of 9 CFU, which correspond to 72 hours of lessons.
The theoretical topics of the course are mainly addressed through lectures, alternating with lessons (or portions of them) of a Socratic heuristic nature. During the Socratic heuristic moments, the dialogic comparison with the classroom will be privileged, on basic topics of Lean Production and Quality and Maintenance Management, also in order to bring out any pre-knowledge on the part of the students.
The teacher will try as much as possible to encourage the active participation of the students in these moments.
The final part of the course (approximately 60/90 minutes per lesson in the last 4-6 lessons) will focus on supporting students in writing their group projects (see the Learning Assessment and Evaluation Methods).
In carrying out the group project, students will be required to apply the theoretical concepts learned and the methodological criteria illustrated in the theoretical lessons.
The slides and notes used to support the lessons will be uploaded at the beginning of the course on the MS TEAMS platform, possibly via links to other pages on the network. To download the slides from MS TEAMS, registration for the online course is required.
Non-attending students are reminded to check the available teaching materials and the instructions provided by the teacher via the MS TEAMS platform.
Assessment methods and criteria
The summative assessment of learning involves two distinct moments, to be carried out strictly in the indicated order:
1) a written test, containing 2-3 exercises (total weight of the items 10-20pt), 1-2 open-ended questions (total weight of the items 6-12pt) and 6-10 closed/multiple-choice questions (weight of each question 1pt).
The duration of the written test is 120 minutes. The written test will be graded on a scale from 0 to 30.
2) a presentation of the project carried out in a group. The presentation and discussion of the project is individual, even though it was carried out in a group (groups of 2-3 people). The project, having as its object an assembly game, aims to have students build and map the flow of value, design and balance the cells, and design their power supply. The rules of engagement of the game will be provided right from the start, and the project will serve as a “model” to practically demonstrate the application of the theoretical knowledge acquired during the course.
Each student may prepare the material he/she deems most appropriate in order to illustrate his/her project to the teacher (for example, spreadsheets, presentations, pdfs, or other may be used). During the presentation of the project, the teacher will ask the candidate unstructured questions, in order to evaluate his/her preparation and knowledge of the project itself and of the theoretical part of the course. During the presentation of the project, the student's knowledge, application, independent judgment and communication skills will be evaluated.
The indicative duration of this part of the test is 15-20 minutes for each student. The oral exam will be evaluated on a scale from 0 to 30. The final evaluation will be obtained, in thirtieths, through the arithmetic mean of the scores obtained in the two individual evaluation moments. The summative test is passed if a score of at least 18 points is achieved. Honors are awarded in the case of achieving the maximum score in each evaluation area, or in the case of a final score higher than 30/30. In the case of an evaluation lower than 18/30 the student will be rejected.
Online registration for the exam is MANDATORY in order to take the exam. The grade of the exam is communicated through publication on the Esse3 platform, possibly on the same day as the exam itself. Once the grade obtained has been viewed, the student can choose whether to present the project on the same day as the written exam, or whether to present it in subsequent exam sessions.
Additional info
Reception to be agreed with the teacher close to the lessons.
