Assignment 4

Prepare for class on Wednesday, November 8, 2006
You may complete this in your project groups
You only need hand in Section II for grading, but you may hand in all sections for my comments.
Please place your assignment in the box outside my office or underneath the door (UW1-336)

I. High Level Process Map - The "ValueStream Maps"

Create a process map.  You should put in valuestream metrics as well as convert it perhaps to more graphical display.  You should separate value added vs. non-value added time.

Optional Reading

You may also want to get the valuestream manual that will be placed on reserves.  The book is called "Learning to See". You can also register at lean.org and obtain a free guide(s) to valuestream mapping.

1. Lean Solutions Chapter 1

Helpful Readings

Why feature undergrad rather than graduate papers?  The MBA papers are good, but most are also confidential. There is also something refreshing about reading a simpler paper or presentation. You can elaborate off of these.

PlastiCraft - A power point of the actual valuestream mapping process along with an intervention.  This student, along with his father, ended up purchasing this company at the conclusion of this course.

Dick's Drive Inn - Is there any burger that is greasier? This is an extraordinary example of combining a graphical layout with valuestream metrics. It doesn't give waste vs. value time, but it already makes for a crowded powerpoint.  I think you get the idea.

Cutter & Buck - This was a proposed layout realignment of the local business. The undergrad team took numerous measurements.

Required Homework

1.  Draw a process map, any kind of process map, on a doable and fruitful section of your project.  It doesn’t have to be a large piece, just find a logical piece that’s workable.  You can valuestream it, you can do a swimlane with inserted metrics, you can merge a layout with a valuestream map, whatever makes sense.  Feel free to sketch it, use Visio, or Igrafx . 

II. Lean Production and Operations Management Theory

 

Required Readings for Part II

 

Have you been to lean.org? You have to register but there is lots of free stuff.

 

1. What is the Theory of Constraints, and How Does it Compare to Lean Thinking? - This is an easy read from the Lean Enterprise Institute.  It's easy since you're conversant with the Theory of Constraints from "The Goal".  This article itself is a bit unfair characterizing the Theory of Constraints as being local rather than Global, a point that is raised by a critic.  Nevertheless, it makes a nice bridge between the two approaches.

 

2. The Lean Enterprise Institute - This is a non-profit institute founded by James Womack, the lead creator of Lean Thinking. 

 

Optional Readings

 

These are truly very optional readings.  David Fitzpatrick is one of the foremost consultants on Lean Thinking.  It was his graduate work that formed the basis for some of its American formulation.  (*Remember what I said about graduate students who "translated" their advisors?  It's their articles that should be read, or it's their workshops to attend.*)

 

1.  Aviation Week Editorials On Aerospace -  These were viewed as seminal pieces in the aerospace industry although I suspect that there's more between the lines because these are so brief.  By the way, when you read the word "Aerospace", insert "Boeing".  At least, that was how many read it.

 

2.  Sick Sigma - David inserts his comments again on Six Sigma.

 

Required HW Question

 

1. In a table or simple page, contrast the theory of constraints (in the Goal) vs. Lean.

III. Jeff Morrow Reading