SIMULATOR FOR LEAN MANUFACTURING APPLICATIONS: QUICK CHANGE CASE
We report a case of education in implementing improvements in the industry with results that significantly reduce training time and significantly increase knowledge retention, as a result of an improvement to shorten the learning cycle - deployment to users of lean manufacturing tools.
This research addresses the impact of the transmission of knowledge through the practice of lean manufacturing techniques using physical machines for simulation. It points out that this is a physical simulation to differentiate the concept from that of a virtual simulator. The development of a simulator for lean manufacturing applications has two main components that need to be defined.
The first one is "simulate", we use it in the sense to try and learn in an environment where conditions have doubled appearances and characteristics of real systems, without compromising business productivity. With simulation it has been achieved great success in teaching concepts and processes. The business benefits achieved by companies using simulators for implementing improvements, allows them to compete with their local, national and international counterparts. For companies a short implementation time means the benefits will be enjoyed sooner.
The second refers to the concept lean, a word introduced as a new paradigm, a couple of decades ago, in the book "The Machine that Changed the World" and is synonymous with the Toyota Production System. The essence of it is the search of perfection through decisions based on a long-term philosophy, even at the expense of short-term financial goals. It consists of designing manufacturing in a way that constantly eliminates waste. It is about people, their development, their aspirations and their working environment. It is the solution of manufacturing problems through continuous improvement and training. It is based on knowledge that is learned from practice.
The appearance of lean techniques to solve problems has increased profits in over 50% compared to those obtained in mass manufacturing. The knowledge of these procedures helps operators to improve processes in the production floor, quickly and accurately. Experimentation in Toyota’s way, allows people to test their hypotheses and learn from their successes and failures. In fact it encourages experimentation, promoting the exchange of the comfort zone to uncharted territory.
This work presents a model based on the CDIO model in which the four letters mean Conceive, Design, Implement and Operate. The model presented in this research also includes a renewed analysis of the unmet needs of the market and the strengths that have the companies. It is very helpful to rethink the educational offer in the light of new technologies.
Any focus on improving engineering education must be directed toward these central questions:
• What is the knowledge, skills and attitudes that the engineering student must have completed his studies as?
• What skill level is required?
• How can we ensure that students get these skills?
The development of a simulator for lean manufacturing applications, to represent real situations that happen in the industry and once built improves learning these techniques through experimentation.