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A Metric-based, Hands-on Quality and Productivity Improvement Simulation Involving Lean and Sigma Concepts For First-year Engineering Lab Students
| Content Provider | Semantic Scholar |
|---|---|
| Author | Allam, Yosef Sink, Scott E. Cerrato, Joseph M. Merrill, John |
| Copyright Year | 2012 |
| Abstract | A new hands-on quality and productivity lab involving lean and six sigma concepts for first-year engineering students was created at the First-year Engineering Program within the Engineering Education Innovation Center at The Ohio State University. The quality and productivity lab is approached in three phases. First, students are presented introductory material in the regular (non-lab) class period prior to the lab session. This first class session starts with an overview of typical organizational departments and functions, the importance of engineering as it relates to management and production, and how lean practices can impact profit. Students are also assigned roles for the lab activity and given basic information and terminology about lean, sigma, and production operations. Students are also assigned a pre-lab exercise to reinforce roles, terminology, and concepts. At the start of the lab period, the second phase of the quality and productivity hands-on lab, students immediately assume their roles in one of two competing value-adding organizations or as the organizations’ customers. The mock organizations produce a real product with six variants. Students run the line in this relatively inefficient default setup and record data. Students must consider the results of key metric calculations from data collected in making process improvements through facilities layout changes, personnel changes, line balancing, converting from a push to pull system, improving communications, etc. Students are then left on their own to cooperatively deliberate, problem solve, and reorganize their production systems to achieve profitability using the terms, concepts, and analytical approaches they have gleaned. After a second production run, data is entered into the scorecard again and key metrics are again calculated. Production lines typically improve and show profit in the second run. In the third phase of the quality and productivity lab, students complete a team technical writing assignment to report the results of the lab and discuss further improvements. Students create visual aids representing the layout and performance of the lines and discuss hypothetical situations gauging the depth of their understanding of quality, productivity, lean, and sigma concepts. Student survey feedback indicates students favor the lab and enjoy the activities and problemsolving with peers. Instructional staff training required on production systems concepts for those lacking industrial engineering backgrounds, lab setup and parts procurement for the product assemblies, and classroom and lab logistics preparation and management present the most significant challenges to running the quality and productivity lab. |
| File Format | PDF HTM / HTML |
| Alternate Webpage(s) | http://www.asee.org/file_server/papers/attachment/file/0002/2987/ASEE_2012_Quality-Productivity_FINAL_03162012_SUBMIT2.pdf |
| Alternate Webpage(s) | https://peer.asee.org/a-metric-based-hands-on-quality-and-productivity-improvement-simulation-involving-lean-and-sigma-concepts-for-first-year-engineering-lab-students.pdf |
| Language | English |
| Access Restriction | Open |
| Content Type | Text |
| Resource Type | Article |
