Lean Management

Couse Leader: Joanna Czerska and Anna Wendt

Home Institution: Gdansk University of Technology, Faculty of Management and Economics, Department of Engineering, Management and Quality

Course pre-requisite(s): semi advanced Excell

 

Course Overview

2 weeks programme, incl.:
• 42h of classroom activities (simulation game, case study, 2 mini projects)
• 14 h of students’ own work (process observations and analysis, projects development)

Learning Outcomes

• The student has a basic knowledge of Lean Management and is able to apply its key rules in simulated process
• The student has developed the skill of teamwork based on team values, developed critical thinking and is open to discuss problems, own ideas and ready to find consensus
• The student is able to assess the process and indicate its inefficiencies
• The student has a basic knowledge of Problem Solving and is able to apply it in practice (project)
• The student has a basic knowledge of key Lean toolbox and knows when and why these tools should be used.

Course Content

Day 1:

Classroom: Introduction to Lean Management and Lean leadership .

Method: lecture + workshops

Hours: 4

Day 2:

Classroom: Building experience in Lean management part 1 - from customer needs to product and process design to dayly management of process results.

Method: simulation game in lean service

Hours: 5

Day 3:

Classroom: Building experience in Lean management part 2 - from process design to daily management of process results.

Method: simulation game in lean service

Hours: 5

Day 4:

Classroom: Learning to see using Makigami part 1 - current state analysis

Method: case study in lean service

Hours: 4

Day 5:

Classroom: Learning to see using Makigami part 2 - future state design and action plan preparation

Method: case study in lean service

Hours: 4

Day 6:

Classroom: Introduction to Problem solving

Method: life case study

Hours: 4

Project - own work: Project 1: Learning to see the real process - problem statement

Method: real process observation

Hours: 3

Day 7:

Classroom: Project 1: Current state mapping

Method: real process analysis

Hours:4

Project - own work: Project 1: Learning to see the real process (additional observations) + Makigami project development

Method: real process analysis

Hours: 3

Day 8:

Classroom: Project 1: Future state designing and action plan preparation

Method: disussion and project assesment

Hours: 3

Classroom: Project 2: Skills management: skills matrix and development plan

Method: Lean Taboo Game and workshop

Hours: 1

Project - own work: Gathering knowledge on Lean Tools

Method: Lean Taboo Game and workshop

Hours: 3

Day 9:

Classroom Project 2: Skills management: one-point lessons and cross-training

Method: Lean Taboo Game and workshop

Hours: 4

Project - own work: Lean Toolbox project development

Method: own work

Hours: 3

Day 10:

Clasroom: Summary, Reflection & Test: Team work - Knowledge - Skills

Method: Lean Taboo Game + workshop

Hours: 4

Total: 56 Hours

clasroom = 42 hours

project - own work = 14 hours

Instructional Method

Key methods planned to be used are mentioned in table above.
The structure of each session is up to 25% knowledge (lecture) and minimum 75% practice (games, workshops, case studies, project).
The general idea of the course is based on team-based learning by doing. Size of teams will vary from 2 to 15 prs. depending on the topic.

Required Course Materials

The classroom
• For each session there is a need of classroom with small and movable tables (school tables for max 2 prs.) which can be easily rearranged according to the students’ and activities’ needs

• The classroom should have 2 or 3 walls where we can hang flipchart cards or A1 printings and work on them

• Loudspeakers are desirable

• Projector

• Whiteboard

• Flipchart stand

Important: Between day 2 and day 3 sessions classroom should not be cleaned as we need to come back to process as we left it day before. If there will be not such a possibility we need to know it.
Important: It is desirable for all classes to be held in the same room. If there will be not such a possibility we need to know it.

Materials

• Printed materials for each student will be prepared and sent to be printed
• Post-it notes – one set of 100 per 3 students
• Flipchart paper – 40 pcs or Easyflip foil 2 pcs of 20m
• White paper A4 – 500 pcs
• 2 sets (4 colours) of whiteboard markes
• Simulation game set per 15 students
o adhesive tape - 4
o stick glue - 2
o blue markers - 6 pcs
o black markers - 4 pcs
o red markers - 2 pcs
o green markers - 2 pcs
o scissors – 2 pcs
o printings A1 – 3 pcs (will be sent to be printed)
• Lean Taboo
o White paper A3 – 60 pcs
o Taboo cards (we will bring them)
o Printing A1 – 1 pcs (will be sent to be printed)
o Set of thin markers (basic colors) – 1 set/student

Books

• This Is Lean: Resolving The Efficiency Paradox, Modig Niklas, Ahlstrom Par
• The Goal: A Process of Ongoing Improvement, Goldratt Eliyahu M., Cox Jeff, Whitford Davi
• Toyota Talent: Developing Your People the Toyota Way, Liker Jefferey K., Meier David.
Students should have their laptops or tablets during day 6, 7, 8, 9 with access to the internet. We will be using MS Excell and Internet

Assessment

(A description of the means of evaluation to be used in the course: The purpose of evaluation is to provide feedback to students on their learning, as well as to permit the instructor to assign a fair grade at the end of the course. Providing explicit information about assignments and grading procedures will clarify expectations and allay student anxiety, while supporting students in pacing their studies, gauging their progress, and achieving learning outcomes. )
1. My development plan document (25%)
• each student at the beginning of the course is defining his/her development plan basing on min-max conditions which will be the fundaments of their personal needs connected with the course topic and course content
• development plan will be controlled by the end of each session using i.a. the individual reflection based on kata coaching questions:
• what is my development plan?
• where am I according to my development plan?
• what I have learnt from my mistakes and successes?
• what were my main challenges and how can I overcome them?
• what I will change during next sessions to overcome my challenges?
• what should be changed during next sessions from teachers’ side to support me in overcoming my challenges?
2. 2 mini projects made in teams (2 x 25%)
• evaluation based on a checklist provided to students prior to the start of the project
3. Knowledge test (25%)
• 30 min during last session

Statement

We are aware of some disadvantages in connection to:
The UDC will pay for the visiting professor's accommodation and meals in a university residence from 17 to 30 July (if necessary, the ISS team may book additional days and the expenses of travel companions, which will be paid by the professor). In the case of two teachers sharing the same course, each of them will be paid for accommodation and meals for one week only.
and accept them.