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LEAN LEARNING ACADEMY (LLA) REFERENCE: 503663-LLP-1-2009-1-BE-ERASMUS-ECUE Ignace Martens, Jan Colpaert, Liesje De Boeck Carlos Vaz de Carvalho, Paulo Ávila, Manuel Pereira Lopes, João Bastos

LEAN LEARNING ACADEMY (LLA) - EURASHE€¦ · leading towards a best-in-class lean production process. After each round productivity and efficiency metrics are visualised on the team

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Page 1: LEAN LEARNING ACADEMY (LLA) - EURASHE€¦ · leading towards a best-in-class lean production process. After each round productivity and efficiency metrics are visualised on the team

LEAN LEARNING ACADEMY (LLA)REFERENCE: 503663-LLP-1-2009-1-BE-ERASMUS-ECUE

I g n a c e M a r t e n s , J a n C o l p a e r t , L i e s j e D e B o e c kC a r l o s Va z d e C a r v a l h o , Pa u l o Á v i l a , M a n u e l

Pe r e i ra L o p e s , J o ã o B a s t o s

Page 2: LEAN LEARNING ACADEMY (LLA) - EURASHE€¦ · leading towards a best-in-class lean production process. After each round productivity and efficiency metrics are visualised on the team

Lifelong Learning Programme (LLP) Erasmus Multilateral Projects Co-operation between Universities and Enterprises projects aim to

bring together these two worlds in order to promoteentrepreneurship, creative thinking and innovative approaches aspart of the curriculum and as a skill for teachers/researchers and toreinforce the link between studies and employment needs.

Scope

Page 3: LEAN LEARNING ACADEMY (LLA) - EURASHE€¦ · leading towards a best-in-class lean production process. After each round productivity and efficiency metrics are visualised on the team

Objective

1. The right way for companies to survive today’s economical crisis is to focus onproduction efficiency and cost reduction. This is what lean manufacturingaccomplishes and the maximum benefit is gained by considering all itselements (principles, tools, mindset) together as a system and by practicingthem every day in a very consistent manner.

2. That’s why all companies need to continuously train their employees in leanmanufacturing principles, tools and mindset.

3. Higher educational institutions should enhance the employability of theirstudents by introducing lean manufacturing into their course programmes.

4. A pedagogically innovative, state-of-the-art course in lean manufacturingbuilt in tight cooperation with experienced lean companies gives studentsan excellent opportunity to learn/practice the lean concepts.

5. A simulated production environment (Lean Production Game) makes it moreattractive, resulting in more motivated students and higher study yields.

Page 4: LEAN LEARNING ACADEMY (LLA) - EURASHE€¦ · leading towards a best-in-class lean production process. After each round productivity and efficiency metrics are visualised on the team

Deliverables

17 course modulesabout lean topics

A lean productionsimulation game

Course 15:

Course 14:

Course 03:

Course 02:

Course 01:

Languages

Page 5: LEAN LEARNING ACADEMY (LLA) - EURASHE€¦ · leading towards a best-in-class lean production process. After each round productivity and efficiency metrics are visualised on the team

Experiential Learning Cycle

Page 6: LEAN LEARNING ACADEMY (LLA) - EURASHE€¦ · leading towards a best-in-class lean production process. After each round productivity and efficiency metrics are visualised on the team

Experiential Learning Cycle

Motivation: Full attention Control: Responsability for actions and decisions Interactivity: Immediate feedback Learning from Failure: Risk taking, hypothesis testing Competition and/or collaboration: Social skills, teamwork, leadership Flexibility: Change Well sequenced problems: Simple to complex Mastery/frustration/fairness: Fair challenge Expertise cycle: Cycles of action and practice

Page 7: LEAN LEARNING ACADEMY (LLA) - EURASHE€¦ · leading towards a best-in-class lean production process. After each round productivity and efficiency metrics are visualised on the team

Lean Elements

• Operating system• Collection of tools and techniques used to run a manufacturing system

under optimal conditions. Safety assurance, problem solving, qualityassurance, visual management, variability reduction, processimprovements, process measurements, total productive maintenance andstandardized work are only a few examples.

• Mindsets and behaviours• Focus on lean behaviour. Each employee needs to understand and get

acquainted with the lean manufacturing mindset. By doing so, everyemployee is directly involved in the continuous improvement efforts of thedirect work environment and the business process.

• Managerial issues• Focused towards leaders such as superintendents, production leaders,

quality, and logistic managers. Specific management tools like policydeployment, confirmation process, time and date management, coachingand assessment are also part of it.

Page 8: LEAN LEARNING ACADEMY (LLA) - EURASHE€¦ · leading towards a best-in-class lean production process. After each round productivity and efficiency metrics are visualised on the team

Lean Production Simulation Game

• Lean concepts into a small scaled production line.• 5S, standardised work, line balancing, setup time reduction, one piece

flow, layout optimisation, JIT/kanban, push and pull production, customerorder decoupling point and many others.

• Lean behaviour is trained during the lean production game by keepingparticipants’ attention on a number of safety rules.

• During a round, a PC programme graphically visualises customer lead timeand a beamer projects it on a wall to allow participants to follow up customerorders.

• By running several production rounds, the process improvements areleading towards a best-in-class lean production process. After each roundproductivity and efficiency metrics are visualised on the team board anddiscussed in the team.

• During the entire course the participants are part of a team of seven to ninepersons. Each team has its own fully equipped team corner with visualisations,performance measurements, team management tools, follow-up instrumentsand communications.

Page 9: LEAN LEARNING ACADEMY (LLA) - EURASHE€¦ · leading towards a best-in-class lean production process. After each round productivity and efficiency metrics are visualised on the team

Lean Production Simulation Game

Page 10: LEAN LEARNING ACADEMY (LLA) - EURASHE€¦ · leading towards a best-in-class lean production process. After each round productivity and efficiency metrics are visualised on the team

Academic partners Company partners

Partners

Page 11: LEAN LEARNING ACADEMY (LLA) - EURASHE€¦ · leading towards a best-in-class lean production process. After each round productivity and efficiency metrics are visualised on the team

Representatives (potential beneficiaries) from SME’s

Review all deliverables published on the website and will formulate feedback

to the academic partner to be included in his presentation,

Form a Lean Community of Practice

Resonance Group

Page 12: LEAN LEARNING ACADEMY (LLA) - EURASHE€¦ · leading towards a best-in-class lean production process. After each round productivity and efficiency metrics are visualised on the team

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Schedule

01/10/’0901/06/’10 01/01/’11 01/08/’11

01/10/’1101/11/’09

Meeting 2Rzeszow (PL)

Meeting 3Gent(BE)

Meeting 4Porto(PT)

Meeting 1Skövde(SE)

WP 1

WP 2

WP 3

WP 4

WP 5

WP 6

WP 7

WP 8

WP 9

WP 10

Management

Website

Create lean course modules

Create lean game concept

Establish game set-up

Translate course modules

Test and implement LLA in curricula

Dissemination

Monitoring

Mainstreaming and multiplication

NM 1 NM 2+ RG

NM 3+ RG

NM 4+ RG

NM 5+ RG

NM 6+ RG

NM 7+ RG NM 8

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• A good simulation game confronts trainees with the results of theirproposed actions. It gives them a huge impact of certainimprovement actions on KPI’s.

• The simulation game must create a unique learning experience forthe trainees that keeps them motivated.

• Lean thinking must be applied to the game development andcontinuous improvement is required. Trainees should report ontheir learning experience afterwards which implies new directions inthe storyboard of the game.

• Developing, but also preparing and coaching a simulation game isvery demanding. It is a team effort, not an individual one.

Success Factors