ISCOM472-LEAN ENTERPRISE Course Description This course provides a lean enterprise / operational excellence process improvement overview and company best practices implementation. Both manufacturing and services / office environment will be explored to address fundamental improvement practices. Problem solving, business flowcharting, process performance data collection and analysis, and the removal activities determined as wasteful or non-essential are explored. Academic Resources Links Library Instructions Review the Links Library. SupportingMaterial Links Library Writing and Style Guidelines (APA) Instructions Review the Writing and Style Guidelines (APA). SupportingMaterial Writing and Style Guidelines (APA) New APA Paper Template: 300-499 Instructions Review the New APA Paper Template: 300-499. SupportingMaterial New APA Paper Template: 300-499 Familiarize yourself with the textbooks used in this course. Instructions Go to Week 1 of this class to begin reviewing the following texts for this course: Krajewski, L. J., Ritzman, L. P., & Malhotra, M. K. (2016). Operations Management: Processes and Supply Chains (11thed.). Upper Saddle River, NJ: Prentice Hall. Vollmann, T. E., Berry, W. L., Whybark, C., & Jacobs, R. (2011). Manufacturing Planning and Control for Supply Chain Management (6th ed.). New York, NY: McGraw-Hill. Wedgwood, I. (2007). Lean Sigma: A Practitioner’s Guide. Upper Saddle River, NJ: Prentice Hall. Faculty and students/learners will be held responsible for understanding and adhering to all policies contained within the following two documents (both located on your student website): Week1 Introduction to Lean Enterprise ASSIGNMENT #1 WK1-Team Selection Assignment 1 Instructions: Form your team and post your selected organization that will benchmark against Toyota while suggesting improvements and the change process to the Assignment Files tab along with the details below. Choose a public company that is listed in the stock market that your team thinks needs improvement with data easily found on the Internet. Post the name of the company and why you chose it related to the Week 2 through Week 5 assignments below. You should not choose companies like Walmart, GE or other well-known companies that have used the tools you will learn in this class; most major process improvements are already completed at these companies. Write 350 words with explanations in paragraph or bullet form. Your team ideas should address all Weeks 2-5 assignments and how your team’s selected company needing improvement relates to each assignment requirement. Give details on the “what” not the “how” your team will improve by working together. In Week 2, your team will select (benchmark) a company needing improvement. In Week 3, your team will map a process (As-Is) and explain some processes that may need to be fixed. In Week 4, your team will fix the process (To-Be). In Week 5, your team will explain how you can measure to monitor the process and work toward continuous improvements. Write a 350-word paper addressing the following: Describe the selected company and why it needs lean enterprise improvements. Describe two processes and your team’s plan to map As-Is process flowchart. Describe some ideas how to fix the processes and map To-Be process flowchart. Describe how your team will examine and use measures, metrics, value stream mapping and continuous improvement. Click the Assignment Files tab to submit your team’s selected company and plan. SupportingMaterial:Team Selection Assignment 1 Grading Guide ASSIGNMENT #2 WK1-Lean Enterprise Organization Application Instructions: You will research the elements and core disciplines of various Lean Enterprise/Operational Excellence initiatives/approaches (for example Lean, Six Sigma, TQM, Theory of Constraints, ISO, Operational Excellence) for both manufacturing and services as it relates to your organization (or one with which you are familiar). Write a 1,050- to 1,400-word paper in which you address the following points: Describe briefly at least two core elements of Lean that you personally can use to improve your own organization or one you know. Compare/contrast at least two operational excellence (Six Sigma, TQM, Theory of Constraints, ISO, etc.) approaches to a Lean Enterprise in the simple matrix given below. Note: Matrix will need to be included in paper. Evaluate how your selected organization’s (your own or one you have chosen) vision supports Lean. If the organization’s vision does not support Lean, re-write it yourself so that it does, and describe how your new version of the vision supports Lean showing old and new forms. Assess how Lean Enterprises and/or other Operational Excellence initiatives/approaches can help lead an organization to change. Six Sigma TQM Theory of Constraints ISO Compared to Lean Contrasted to Lean Note: Pick at least 2; you can choose others. Format your paper consistent with APA guidelines. Use a minimum of 3 different references that are not from the same online text, library book or article. Submit your assignment to the Assignment Files tab. SupportingMaterial:Lean Enterprise Organization Application Grading Guide Week2 Existing Work Process ASSIGNMENT #1 WK2-Benchmarking to Toyota Instructions: Attain final faculty approval of your team’s selected organization for improvement selection from Week 1. Research Toyota Production System (TPS) and Toyota Lean Enterprise solutions and also the team’s selected public organization that needs improvement. Write a 1,050-word paper in which you Benchmark/Baseline a Lean Enterprise organization against Toyota. Compare and contrast your chosen organization needing improvement to Toyota that already practices lean enterprise best practice and initiatives. Address each of the following in your paper: Benchmark/Baseline your selected public organization needing better Lean Enterprise solutions to Toyota. Compare and contrast the management style(s) and other operating principles within your selected organization needing improvement with Toyota’s. What differences or similarities do the two organizations have in vision, mission, values, and/or objectives? Describe the characteristics and best practices benchmarked for your selected organization’s lean enterprise style(s) and how they affect organizational behavior. Compare those characteristics with Toyota’s. Evaluate how the benchmarked best practices can be integrated into your selected organization. Explain how Benchmarking/Baselining can facilitate the change process to improve efficiency and eliminate waste. Format your paper consistent with APA guidelines. Use a minimum of 3 different references that are not from the same online text, library book or article. Use the Grading Rubric and University Library Sample Paper and APA Guide and Citation Generator. Click the Assignment Files tab to submit your assignment. SupportingMaterial:Benchmarking to Toyota Grading Guide Learning team Jan 18, 2016 11:59 PM 5 ASSIGNMENT #2 WK2-Individual Article Summary Instructions: Research and select an article(s) from the Week 2 Electronic Reserve Readings. Summarize the article(s) you have chosen in a 350-word paper. Explain how your selected article(s) relate(s) to two of the five Week 2 Objectives. Week 2 Objectives: Existing Work Process: 2.1 Categorize process analysis techniques which are utilized at the various phases of process improvement. 2.2 Explain how baselining and benchmarking are vital to the change process 2.3 Identify three categories of process improvements that may be applied to organizations 2.4 Examine the benefit and importance of accurately documenting the As-Is Process. 2.5 Create an As-Is Process flowchart. Reference the article according to APA guidelines. Click the Assignment Files tab to submit your assignment. SupportingMaterial:Individual Article Summary Grading Guide Week3 Work Process Improvement Identification ASSIGNMENT #1 WK3-Process Improvement Opportunities Instructions: Create an As-Is Process Flowchart for a process that requires improvement of your selected organization. Explain the benefits of accurately documenting the As-Is process. Research your organization that needs improvement and your benchmark organization. Write a 700-word paper in which you identify and explain the process improvement opportunities and change management process and map the current AS-IS process. Address each of the following in your paper: Explain why process flowcharts to map the As-Is process is important to problem solving. Use the matrix example given below to identify and benchmark process improvement categories: Identify and explain the following terms: Reduced lead-time/cycle-time Improved quality Elimination of waste Reduced total cost process improvements. Use the process above to benchmark these four categories against Toyota Production Systems (TPS) lean enterprise best practices. Describe challenges the selected organization may face in implementing the areas for improvement. Explain the importance of the current As-Is Process. Identify potential consequences of incorrectly completing the As-Is flowchart Map at least two of the Matrix As-Is process improvement categories for your selected organization. Use flowcharting process map boxes (spaghetti and/or swim lane) and at least two decision trees/blocks in the charting. Include your As-Is Flowchart as an exhibit or figure in your paper. Process Improvement Categories Definitions (Identify and Explain) Toyota (Best Practice) Description Reduced Lead-Time / Cycle-Time Improved Quality Elimination of Waste Reduced Total Cost Format your paper consistent with APA guidelines. Use a minimum of 3 different references that are not from the same online text, library book or article. Submit your assignment to the Assignment Files tab. SupportingMaterial:Process Improvement Opportunities Grading Guides ASSIGNMENT #2 WK3-DMAIC Problem Solving Instructions: Create a Microsoft PowerPoint slide presentation with speaker notes addressing each of the process improvement phases of DMAIC. Identify a process you want to improve in your personal life or in your organization, or one you know that may benefit from improvement. Research each of the following phases: Define Measure Analyze Improve Control Describe two different tools/techniques, using one slide per each phase of DMAIC and two tools/techniques per each phase, 3 slides total each phase, to analyze a process you have chosen to improve. Use 5 Whys and 5S as two of your 10 selected tools/techniques. You may choose the other eight tools/techniques.For each phase, provide applied examples of process improvement within your workplace or an organization with which you are familiar and apply tools/techniques to each phase. Define Tool 1 Tool 2 Measure Tool 1 Tool 2 Analyze Tool 1 Tool 2 Improve Tool 1 Tool 2 Control Tool 1 Tool 2 Tools/Techniques are from the text / toolbox such as 5 Whys, 5S, Flow Charts, Pareto Charts, Control Charts, Scatter Diagrams, Brainstorming, etc. Note: You need to show detail in the speaker section. This is worth 15 points (15% of your grade) so please give details of how the tools/techniques are used, and give examples. Format your PowerPoint presentation consistent with APA guidelines.The presentation will need to be 19 slides and include the following: title slide, introduction, content, conclusion and reference slide. Each phase must have one description slide plus two slides for each technique/tool chosen and must also provide examples and personal application on the slide with details in the speaker notes. Use a minimum of 3 different references that are not from the same online text, library book or article. Click the Assignment Files tab to submit your assignment. SupportingMaterial: DMAIC Problem Solving Grading Guide ASSIGNMENT #3 WK3-Article Summary Instructions: Research and select an article(s) from the Week 3 Electronic Reserve Readings. Summarize the article(s) you have chosen in a 350-word paper. Explain how your selected article(s) relate(s) to two of the four Week 3 Objectives. Week 3 Objectives: Work Process Improvement Identification: 3.1 Explain DMAIC and how it is utilized throughout the change management and problem solving processes. 3.2 Examine the 5 Whys and explain how they are an effective tool in change Management. 3.3 Examine the 5S Lean System and explain the advantages to manufacturing or office environment. 3.4 Examine the benefit and importance of accurately documenting the To-Be Process. 3.5 Create a To-Be Process flowchart. Reference the article according to APA guidelines. Click the Assignment Files tab to submit your assignment. SupportingMaterial:Article Summary Grading Guide Week4 Implementation of Lean Initiatives ASSIGNMENT #1 WK4-Recommend Improved Process Applying To-Be Flowchart Instructions: Create and recommend an improved process, applying the To-Be Flowchart for the process identified that requires improvement from Week 3 for your selected organization. Write a 700-word paper in which you describe and apply the two process improvements categories identified in Week 3 along with DMAIC tools / techniques to improve the two selected processes and map the To-Be flow chart. Address the following in your paper: Use the two selected As-Is process flowcharts from Week 2 and improve the process using the process improvement categories selected and benchmarked to Toyota and map the new improved To-Be processes. Describe how you used the Toyota benchmark information to help you improve the two processes. Use at least two new process improvement tools / techniques from DMAIC, one per each Week 2 flowchart, that can help improve your selected processes further and describe how they were implemented. Describe how using DMAIC tools and techniques can help create standardized versus non-standardized processes. Identify potential challenges in implementing your process changes. Recommend how the organization may resolve resistance to change such as communications and implementation plans. Map / design the two new and improved To-Be flowcharts and add to the assignment as an Exhibit or Figure. Format your paper consistent with APA guidelines. Use a minimum of 2 different references that are not from the same online text, library book or article. Use the Grading Rubric and University Library Sample Paper and APA Guide and Citation Generator. Click the Assignment Files tab to submit your assignment. SupportingMaterial:Recommend Improved Process Applying To-Be Flowchart Grading Guide ASSIGNMENT #2 WK4-Leading Lean Enterprises Changes Instructions: Write a 1,050-word paper to assess and resolve resistance to process change. Identify at least two non-standardized processes in your own organization or one you are familiar with that can be documented. Address the following in your paper: Describe the two non-standardized processes selected. Explain why the non-standardized process should be standardized to help reduce variation. If you think a non-standardized process is OK to utilize, explain why and how you will control variation. Evaluate challenges that the selected organization may face in implementing the identified lean enterprise improvements. For example, examine your DMAIC assignment in Week 3 where you improved a process. What are the barriers to implementing these changes? Recommend how your selected organization may resolve resistance to change or overcoming change. Explain how management can help organizations facilitate change with empowerment and getting everyone involved. Format your paper consistent with APA guidelines. Use a minimum of 3 different references that are not from the same online text, library book or article. Use the Grading Rubric and University Library Sample Paper and APA Guide and Citation Generator. Week5 Metrics and Continuous Improvement ASSIGNMENT #1 WK5-Continuous Improvement Applying Measurements and Value Stream Mapping Instructions: Write a 1,050-word paper that recommends and evaluates the final business process improvementplanfor your selected organization. Address the following in your paper: Explain the metrics and processes your team will use to monitor and sustain your planned improvements. Develop the metrics to quantify the level of improvement in your selected processes. Compare and contrast the various measurement techniques your team selected to measure and sustain the new To-Be process. Why were some chosen and others not? Describe what Value Stream Mapping is and how it can be used to help the To-Be Process. Evaluate the most important parts of the Value Stream Mapping. Explain how continuous improvement can help your chosen company monitor processes in comparison to stopping at the To-Be Process mapping phase? Analyze how your team can sustain continuous improvement with the new, improved process. Format your paper consistent with APA guidelines. Use a minimum of 3 different references that are not from the same online text, library book or article. Use the Grading Rubric and University Library Sample Paper and APA Guide and Citation Generator. Click the Assignment Files tab to submit your assignment. SupportingMaterial:Continuous Improvement Applying Measurements and Value Stream Mapping Grading Guide ASSIGNMENT #2 WK5-Just-in-Time (JIT) Process Improvements Instructions: Benchmark a public company that has JIT Processing. Apply the selected company’s JIT best practices to your own company or another public company you know or can research. Observe and document the process steps followed. Write a 1,050-word analysis in which you: Explain the JIT philosophy. Describe the production process steps observed or implemented from the benchmarked company. Attach a “before improvement” process As-Is Flowchart as an Exhibit or Figure. Compare and contrast standardized and non-standardized process steps. State your opinion concerning the process (effectiveness, efficiency, and measurements). Recommend process improvements using supportive evidence. Attach an “after improvement” process To-Be Flowchart as an Exhibit or Figure. Format your paper consistent with APA guidelines. Use a minimum of 3 different references that are not from the same online text, library book or article. Click the Assignment Files tab to submit your assignment. SupportingMaterial:Just-in-Time (JIT) Process Improvements Grading Guide
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