Instructional lean manufacturing lab design using SMED
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Lean manufacturing tools such as 5S, Single-Minute Die Exchange (SMED), pull vs. push and Kanban system, etc., are practical tools that help eliminate waste, increase efficiency, and improve quality in various manufacturing and other systems. In higher education, these tools can be taught to students in a traditional lecture-style model or illustrated as lab activities with hands-on simulation. In the undergraduate manufacturing engineering program under study, lean manufacturing concepts are taught in a Manufacturing Process Planning course. This study presents a tool kit design that provides an instructional learning experience on the principles and tools of lean manufacturing through hands-on activities/simulation that can be easily incorporated into the course curriculum. This project specifically focuses on developing and designing a traditional assembly vs. SMED assembly with the appropriate instruction manuals to help the students connect the theory and practice of this important lean concept. A t-shirt press process was proposed to illustrate this learning experience. Two t-shirt press machines were designed/modified for this project's purpose. One machine followed a traditional press process with fasteners and connectors, while the other machine was modified to incorporate SMED. Additionally, the machines were accompanied by examples of different levels of work instructions to demonstrate the importance of quality work instructions, an essential aspect of lean manufacturing, which is another topic covered in this class.
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2690-3229 (online)

