Lean Engineering Habib University Continuing Education Series:

ABOUT HABIB UNIVERSITYHabib University is a unique liberal arts and sciences university, offering interdisciplinary education in science, engineering, arts, humanities and social sciences. It has been established in Karachi under the patronage of the House of Habib. Committed to providing the highest standards of excellence in higher learning, the University has several formal partnerships including one with Texas A&M University at Qatar. Habib University is a preeminent institution of higher learning, dedicated to enriching individual lives and engaging society through teaching, research and service. Its mission is to educate promising students from all backgrounds and enable them to become competent, caring and critically-conscious members of society. Habib University engages outstanding academics who work with us to enrich the minds and lives of our students, fostering an environment that promotes creativity, academic freedom and an exchange of ideas.

The need for continuing education in the 21st century’s knowledge-based economy is paramount. Knowledge and technology are at the heart and mind of the global economy. The country’s success in the knowledge-based economy depends on the ability of its workforce to respond to new challenges and pursue lifelong learning opportunities.

Habib University’s Office of Research and Continuing Education aims to provide state-of-the-art continuing education courses to fulfill the growing demand for a highly skilled work-force. By providing this essential service we intend to bridge the gap between the needs of the society and the economy. At Habib we have forged collaborations with leading international universities such as Texas A&M University at Qatar and Carnegie Mellon University, USA and hired highly skilled faculty with diverse national and international backgrounds including the United States, United Kingdom, Germany, and Russia.Our international collaborations and highly

qualified faculty allow us to provide courses unlike any other institution. These courses can be arranged in-house at our state-of-the-art campus located in the heart of Karachi as well as Doha and Dubai, depending upon your corporate needs. To help you get the best return on your corporate training investment, Habib University’s Office of Research and Continuing Education can facilitate a needs assessment, and provide proven programs and customized training. ORCE programming staff have extensive experience in adult education, and the instructors are experts in their fields. Together, they can provide you with proven course content and expert delivery that meets your organization's training needs.

For further information contact Habib University’s Office of Research and Continuing Education at orce@habib.edu.pk or visit our homepage at www.habib.edu.pk/orce

CONTINUING EDUCATION

FUNDAMENTAL PRINCIPLE OF LEANAnything that does not add value to the product is waste and must be reduced or eliminated.

An average company wastes 85% of its productive time on non-value added work.

Henry Ford was able to mine ore on Monday and, using that very same iron ore, produce a car coming off the assembly line on Thursday. He did this by focusing on the total elimination of non-value adding wastes.

WHAT IS LEAN ENGINEERING?Lean is a philosophical approach to developing flexible, responsive processes capable of providing your customers with what they want, in the amount they need, exactly when they want it.

LEAN PRINCIPLES1

1. Specify value in eyes of customer.2. Identify value stream and eliminate waste.3. Make value flow at pull of customer.4. Involve & empower employees.5. Continuously improve in pursuit of perfection.

1 Origin: Toyota Production System (TPS)

HISTORY OF LEAN

1850

American Civil War

ELI WHITNEYInterchangeable Parts

FREDERICK TAYLORStandardized WorkTime Study & Work StandardsWorker/Management Dichotomy

Drawing ConventionsTolerancesModern Machine Tool Development

1900

1950

2000

Great War

World War VII

LEAN MANUFACTURING

FRANK GILBERTHProcess ChartsMotion Study

HENRY FORDAssembly LinesFlow LinesManufacturing Strategy

EDWARD DEMING, JURANSPCTQM

EIJI TOYODA, TAICHI OHNOToyota Production SystemJust-in-TimeStockless ProductionWorld Class Manufacturing

ELI WHITNEY

FREDERICK TAYLOR

FRANK GILBERTH

HENRY FORD

TAICHI OHNO

SHINGO

LEAN SYSTEMS1. WORK TO TAKT TIME2. ONE-PIECE-FLOW3. AT THE PULL OF THE CUSTOMER

WHY LEAN?

The World is Shrinking...

The Competition is Growing...

LEAN HELPS TOQUICKLY LEVERAGECOMPANY STRENGTHS

THE COMPETITION IS NOT STANDING STILL

SalesGrowth

ReduceOperating

CostsSimultaneously

• Preserve Access to Market• Grow Domestic Business

• Develop new products

STRATEGY FOR DEPLOYMENT• Start in Manufacturing (Office Lean will follow) • Identify improvement “pilot” project • Train Core teams in Lean methods and techniques (Learn by doing) • Increase formally trained “Lean Transfer” people in the company• Report Monthly with Radar Charts/Success stories

IN THIS LEAN COURSE YOU WILL LEARNProcess improvement techniques that reduce or eliminate non-value added work. This in turn makes processes more efficient in your enterprise, improving productivity & hence profitability, providing you with a competitive edge in your industry.

SO, WHAT DO WE NEED TO DO TO SUCCEED?

MONTHS DAYS HOURS

SPEED

COST

YOUR COMPANY GOALS

REDUCE FLOOR SPACE

LOWER INVENTORY

VISUAL CONTROLSAND DISPLAYS

CREATE A FLEXIBLE WORK FORCE

FOCUS IS ON GENERATING A THOROUGH UNDERSTANDING OF LEAN TOOLS AND HOW TO APPLY THEM IN THE REAL OR PRACTICAL WORLD• Conducting class Kaizens on various projects• Creating VSM or value stream mapping• Understanding of the DMAIC process• Utilizing 6S• Awareness of 8 types of waste• Distinguishing between value added, non value added & necessary evil• Reducing change over /set up time by implementing SMED• Creating a visual work place Kanban• Implementing the pull system• Undestanding of takt time, lead time, cycle time• Defect prevention techniques aso known as Jidoka• Line balancing also known as Heijunka• Creating standardized work or repeatible & stable work practices• The value of TPM or total productive maintanance• Intro to learning curves• Pareto charts• Cause and effect diagrams or fish bone diagrams

WHO NEEDS LEAN & SHOULD LEARN LEANIn a competitive world with a global economy all company employees need lean from the CEO all the way to the factory floor worker. Encompassing the entire enterprise environment including office workers, as we do not want to build only islands of Lean.

COURSE INFORMATION:• This course will be offered in the Spring 2015 semester at Habib University City Campus, located at Plot # 295, Block 18, University Avenue, Gulistan-e-Jauhar, Karachi.• The course comprises of a minimum of 45 hours of class time and will be conducted outside normal working hours.• Recognition by Pakistan Engineering Council for this course has been applied for.• For more information contact the Office of Research and Continuing Education Habib University at orce@habib.edu.pk

COURSE INFORMATION

Mr. Mateen Haider is a process improvement/Lean Engineering specialist, whose forte is interfacing Lean theory with the practical world. His educational background includes a BS in Mechanical Engineering and an MS in Industrial/Lean Engineering. He is also a Certified Six Sigma, Black Belt. The majority of his 37 year career has been in the US Aerospace Industry improving productivity. With a focus on reducing or eliminating non value added activity. His experience has mainly been in the efficient production of aero structures, where a high degree of accuracy is required. Aero structure areas/shops that he has supported & managed include the sheet metal, machine, composites, processing & assembly. Programs that he has supported include: Boeing's 777, 767, 757, 747 & C-17. Lockheed's C-5, Fairchild's A-10, Grumman's A-6, Rockwell's B-1B & Space Shuttle, Sikorsky's Blackhawk & Seahawk, Kaman's SH-2 G & KMAX, GE's CF-6 Thrust reversers. He also teaches Lean Engineering at the college level in Connecticut & consults on the subject. His titles have included Director of Operations, Manager of Industrial/Lean Engineering, Manager of Manufacturing Engineering (ME). In his position as Manager of ME he was responsible for responding to requests for quotes (RFQ's) all the way to producing the product. His voluntary activities include heading, The Citizens Foundation chapter in Connecticut, his Rotary District's scholarship committee, the Institute of Industrial Engineering Chapter 075 MA & CT. For his voluntary activities he also received the state of Connecticut's Immigrant of the Year award for 2010 & a Paul Harris from Rotary. Has great communication skills and is multi lingual in Urdu, Punjabi, English & German.

COURSE INSTRUCTOR

+92 21 38797082twitter.com/HabibUniversityfacebook.com/HabibUniversityhabib.edu.pk

Habib University:Block 18, Gulistan-e-Jauhar, University Avenue, Off Shahrah-e-Faisal, Karachi.