Lean Discussion

Managing and Leading Operations

BUS6030

Week Four

Business Programs

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Week Four Introduction:

We continue to consider capacity problems this week as we look at bottlenecks, those things that keep our processes from meeting demand. At home or at work, on vacation or planning a budget, we often have to deal with constraints. They are barriers that can hold us back from accomplishing the tasks we need or want to complete. This week we will consider different bottlenecks around us and how you can develop skills that allow you to overcome or lessen their impact.

We will also be looking at lean techniques. More and more organizations are utilizing the tools and techniques from lean in order to reduce costs and improve quality. You can utilize lean concepts at work whether your organization adopts lean as a strategy or not. Lean concepts can also be applied to our homes.

Week Four Objectives:

1. Apply Christian principles in critical thinking.

2. Identify bottlenecks and develop remediation for them.

3. Discuss the major components of lean and how they work.

4. Develop strategies for overcoming obstacles to lean system implementation.

5. Apply lean concepts to a project.

Week Four Course Materials:

Jacobs, F. R., & Chase, R. (2013). Operations and supply chain management (14th ed). New York, NY: McGraw-Hill.

Ciarniene, R., & Vienazindiene, M. (2013). Lean manufacturing implementation: The main challenges and barriers. Management Theory & Studies for Rural Business & Infrastructure, 35(1), 41-47.

Taylor, A., Taylor, M., & McSweeney, A. (2013). Toward greater understanding of success and survival of lean systems. International Journal of Production Research, 51(22), 6607-6630.

Upadhye, N., Deshmukh, S. G., & Garg, S. (2009). Key issues for the implementation of lean manufacturing systems. Global Business & Managment Research, 1(3/4), 57-68.

Week Four Reading:

Text: Operations and Supply Chain Management

Chapter 5: Strategic Capacity Management

Chapter 14: Lean Supply Chains

Chapter 23: Theory of Constraints

Article: Lean Manufacturing Implementation: The Main Challenges and Barriers

Article: Toward Greater Understanding of Success and Survival of Lean Systems

Article: Key Issues for the Implementation of Lean Manufacturing Systems

Week Four Schedule:

Learning Activity	Points Possible	Type of Activity	Due Date
4.1 Devotional	5	Discussion	Due by the end of the week.
4.2 Bottlenecks	20	Discussion	Initial postings are due by the fourth day of the week. Responses are due by the end of the week.
4.3 Lean Discussion	20	Discussion	Initial postings are due by the fourth day of the week. Responses are due by the end of the week.
4.4 Obstacles to Implementing Lean	75	Paper	Due by the end of the week.
4.5 Lean Project: Brainstorming Milestone	20	Milestone – Discussion Forum	Initial postings are due by the fourth day of the week. Responses are due by the end of the week.
Total	140

Learning Activity 4.1: Devotional

Therefore, since we are surrounded by such a great cloud of witnesses, let us throw off everything that hinders and the sin that so easily entangles. And let us run with perseverance the race marked out for us, fixing our eyes on Jesus, the pioneer and perfecter of faith. For the joy set before him he endured the cross, scorning its shame, and sat down at the right hand of the throne of God. Consider him who endured such opposition from sinners, so that you will not grow weary and lose heart.

Hebrews 12:1-3

The writer of Hebrews talks in Chapter 11 about the faithfulness of many who had lived and died in the faith. In Chapter 12 the writer calls on us to be faithful as well. The first way we can remain faithful is to “throw off everything that hinders and the sin that so easily entangles.” The writer pictures a runner who strips down to the bare essentials before running a race so that all the excess weight is gone. What a great picture of “lean” this presents.

In its simplest form, lean is the unending elimination of waste. As Christians, this is what we are called to do as well. We must continually work to get rid of self and be more like Christ. Self is waste in the Christian life. Author and speaker Beth Moore says the closer we get to Christ, the pickier He gets. Let us carefully consider where we can get lean in our walk with Christ.

Objectives

· Apply Christian principles in critical thinking. (4.1)

Instructions

1. Read the devotional and consider the idea of “getting rid of waste.” In the discussion forum,

a. How do you see that concept correlating to your walk with Christ?

b. Where can we get lean in our walk with Christ?

2. Post your thoughts in the discussion forum titled Wk4 Devotional.

3. Responding to the posts of other students is not required, but is encouraged.

4.1 Devotional

Points: 5

Learning Activity 4.2: Bottlenecks

Introduction and Purpose of Assignment

Nearly every process reaches a point where the demand for a product or service exceeds the ability of part of the process to meet the demand, this causes a bottleneck. The ability to identify and remediate bottlenecks is a tool that Operations Management can offer a manager.

Objectives

· Identify bottlenecks and develop remediation for them. (4.2)

Theory and Context

Bottlenecks can occur for a variety of reasons. These can occur due to machine hours availability, limited skilled labor, or a specific resource that is scarce. While bottlenecks are typically viewed as a negative aspect to production, they serve a purpose to inform management about capacity. Where no bottleneck exists there is excess capacity. A business operating efficiently wants to minimize excess capacity, so there is a balance between capacity and bottlenecks that needs to be managed.

Resources

Barrett, K., & Greene, R. (2012). Constraints management breaks down barriers to efficiency. Governing. Retrieved from

http://www.governing.com/columns/smart-mgmt/gov-constraints-management-breaks-down-barriers-to-efficiency.html

Instructions

1. Consider processes that you are familiar with that have a bottleneck. The bottlenecks can be seen at work, banks, restaurants, stores, etc. In the discussion forum consider the following:

a. What is the process and where is the bottleneck in the process?

b. How can this constrained process be fixed? Avoid the easy fix of just hiring more people.

2. Post your responses in the discussion forum titled Wk4 Bottlenecks.

3. Use the Discussion Rubric below to ensure you have met all the criteria for this assignment.

Grading Guide or Rubric: Discussion Rubric

4.2 Bottlenecks

Points: 20

Learning Activity 4.3: Lean Discussion

Introduction and Purpose of Assignment

Lean techniques can be used in a variety of manufacturing and service organizations. This discussion should encourage you to think beyond a textbook application of lean to manufacturing operations to a broader application of the concept of “Lean.”

Objectives

· Discuss the major components of lean and how they work. (4.3)

Theory and Context

Lean is a multi-faceted system of continuous improvement and waste elimination. Organizations ranging from hospitals to automotive manufacturing companies have seen the positive results of lean implementation. A thorough understanding of lean concepts will benefit the manager of any organization.

Resources

The website referenced below has multiple tabs detailing different lean concepts.

United States Environmental Protection Agency. (2015). Lean thinking and methods. Retrieved from http://www.epa.gov/lean/environment/methods/index.htm

Instructions

1. Consider how lean might benefit an organization you are familiar with. If this organization has already implemented lean, then consider in which areas it could be improved.

2. Discuss two or more of the lean concepts and how implementing these concepts in an organization you are familiar with would make it better. If this organization has already implemented lean then discuss which two or more of the concepts could be better utilized and how that might occur.

3. Post your responses in the discussion forum titled Wk4 Lean Discussion.

4. Use the Discussion Rubric below to ensure you have met all the criteria for this assignment.

Grading Guide or Rubric: Discussion Rubric

4.3 Lean Discussion

Points: 20

Learning Activity 4.4: Obstacles to Implementing Lean

Introduction and Purpose of Assignment

Lean can only benefit an organization if it is successfully implemented. Employees often see lean as strictly a headcount reduction tool and therefore make a successful implementation difficult, if not impossible.

Objectives

· Develop strategies for overcoming obstacles to lean system implementation. (4.4)

Theory and Context

Consider the difficulties in implementing lean systems into an established organization. Some of your reading discusses these issues. A significant body of literature exists especially in quality and Six-sigma journals, regarding the difficulties in implementing lean.

Instructions

1. Write a 3-4 page paper that discusses how to overcome obstacles to lean systems implementation.

2. To achieve maximum points for content and analysis, the following elements need to be thoroughly addressed:

a. Research the topic of overcoming obstacles to lean implementation as evidenced by citations.

b. Identify two or more issues (difficulties) with lean implementation.

c. Explain the obstacles and what management could do to overcome each of the obstacles.

3. Meet expectations provided in the Paper Writing rubric.

4. Provide at least three academic references.

5. Submit the paper to your facilitator as an attachment in the dropbox titled Wk4 Obstacles to Implementing Lean by the end of the week.

Grading Guide or Rubric: Paper Writing Rubric

4.4 Obstacles to Implementing Lean

Points: 75

Learning Activity 4.5: Lean Project:

Brainstorming Milestone

Introduction and Purpose of Assignment

A manager’s ability to implement a lean project is a significant skill to have, regardless of the type of organization in which they are employed.

You will be writing a final paper regarding a lean project. The project will be worked on in sections this week and the next two additional weeks.

Objectives

· Apply lean concepts to a project. (4.5)

Theory and Context

The beginning of a well-written project is the selection of an appropriate project. This activity involves selecting a project and getting the approval of your instructor.

Consider a lean project at work or home that you could write about. This must be an original project that has not been accomplished yet or is not currently in process. Two examples of projects are: 1) 5-S an area of the department or one’s garage or 2) implement a kanban in the reordering processes for supplies at work or at home.

The project must be large enough to include other people. For example, doing a 5-S project on one’s work area is not a proper project, but doing a 5-S project on the family garage which requires assistance from all family members to maintain, would be acceptable.

Resources

Fourprinciples. (2012). Four principles lean management – Get lean in 90 seconds [Video file]. Retrieved from https://www.youtube.com/watch?v=wfsRAZUnonI

Instructions

1. Read the information above to gain familiarization with the requirements for this project.

2. Select a project around your home, at work, for your church, to help a public service provider, or other.

3. Make sure the project can benefit from a lean implementation.

4. The project requires you to include others to complete the process.

5. In the discussion forum, present your project idea to the class to foster discussion and brainstorming ideas.

6. Post your proposed project to the discussion forum titled Wk 4 Lean Project: Brainstorming Milestone by the fourth day of the week.

7. Provide comments, questions, and suggestions for at least two of your classmates by the end of the week.

Grading Guide or Rubric: Assignment will be scored based on the completeness of the submission and your responses to your classmates. The facilitator will provide feedback indicating if your project needs refined, and will approve or disapprove the project. Mechanics, and grammar will be considered in the assigned grade.

4.5 Lean Project: Brainstorming Milestone

Points: 20