Using Lean to Develop Partnerships between Students and Industry

Dr. Jim Keyes College of ManagementInspiring Innovation. Learn more at www.uwstout.edu

UW Stout Wisconsin’s Polytechnic University

Mission:

University of Wisconsin-Stout is a career-focused, comprehensive polytechnic university where diverse students, faculty and staff integrate applied learning, scientific theory, humanistic understanding, creativity and research to solve real-world problems, grow the economy and serve a global society.

@ACBSPAccredited #ACBSP2015

Dr. Jim Keyes College of ManagementInspiring Innovation.

UW Stout Facts

• Enrollment• 9,371 fall 2014 • 88% Undergraduate• 12% Graduate

• Programs• 44 Undergraduate• 20 Graduate

• Employment of graduates • 97.1% 2013

• Degrees Awarded 2013-2014• 1,643 Undergraduate• 289 Graduate

@ACBSPAccredited #ACBSP2015

Dr. Jim Keyes College of ManagementInspiring Innovation.

College of Management

Departments• School of Hospitality• Business• Operations and

Management• Military Science

Undergraduate Programs• Business Administration*• Retail Merchandising

and Management*• Supply Chain

Management*• Management*• Hotel, Restaurant and

Tourism Management• Golf Enterprise

Management

• Real Estate Management• Sustainable

Management

Graduate Programs• Operations and Supply

Management*• Risk Control• Sustainable

Management• Training and Human

Resource Development

@ACBSPAccredited #ACBSP2015*ACBSP Accredited Programs 2012

Lean:The process of doing more with less

• Broader range of goods

• Fewer inputs – more outputs

• Lower costs

• Higher quality

• Shortened lead times

• Continuous improvement

• Waste elimination

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Value of Lean Before..

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Value of Lean Since…

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Need for Lean Training

• 2003 survey by DemandStream 280 manufacturers • 40% of U.S. manufacturers use Lean as their primary

business strategy

• 2007 IndustryWeek/ Manufacturing Performance Institute Census of Manufactureres • 60% of manufacturers reported using lean

• 2010 Survey of Graduated students from UW Stout • 52% were using lean

@ACBSPAccredited #ACBSP2015

Need for Lean Training

• Monster.com indicated 975 “lean” positions posted in October of 2006

• The same search recently indicated 2,253 “lean” positions available

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Lean Enterprise Institute

• Working to implement Lean education in academic settings

• LEAN – Lean Education Academic Network• 30 professors in 2005 • 99 professors in 2009• 132 professors in 2015• Acknowledge lack of dedicated courses• Understand the lack of material and training• Working to develop and database to share course

material

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Applications of Lean

• Presently dominated by manufacturing, by large producers

• New Users• Small shop manufacturers• Service industries• Back-office• Sourcing• Logistics• Retail• Healthcare

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Student Audience for Lean Training

• Technology

• Engineering

• Business

• Supply Chain

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Course Development

• Utilizing the Lean training that employers presently find value in to scope the lean course.

• Five Primary Elements• Specifying Value• Identifying the Value Stream• Flow• Pull• Perfection

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Course Outline

• Definitions - Vocabulary

• Methodologies

• Standardization

• Culture

• Empowerment

• Visual control

• Application

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Using Lean to Partner with Industry

• Industry is using lean tools

• Students are learning lean

• The Polytechnic approach is application

• Natural fit to work with industry to help them improve while improving the learning of UW Stout students

@ACBSPAccredited #ACBSP2015

Course Outline

Divided between the Classroom

five weeks instruction, demonstrations and readings

nine weeks of application based learning

at Gemba working with clients

Observing, development and implementation

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Projects begin with an A3 Report

• Standardized storytelling•Not solving the problem• Identifying the issues• A plan to address the issues• Visual tool to manage the project

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Industry Project Examples

• Actual student projects from the past few years• Major and small corporation• Large and small impacts

• Always a great learning experience for both the client and students

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Results from New Layout

Steps Set Up Final Initial Steps 50 134Steps After Changes Made 32 73% Reduction 36% 46%

Test Wall Estimated Steps

50

134

32

73

0

20

40

60

80

100

120

140

160

Set Up Final

Estimated Amount of Steps

Refill Line

• Suggestion: Add a refill line to each bin.

• Benefit: Adding a refill line will alert workers when hardware levels are low and should be replenished. This will ensure that the process will not stop as a result of not having enough hardware.

@ACBSPAccredited #ACBSP2015

Pulley Assembly

• Total Non-value Added time = 13 + 6 + 7 + 90 + 4 = 120 seconds = 2 minutes

• This time is wasted with each pulley that is built

Recommendation

• Talk to supplier to discuss changes in packaging

• A reduction in this waste improves efficiency

• Less packaging should reduce cost from supplier@ACBSPAccredited #ACBSP2015

Typical Semester Corporate Projects

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• Five to six projects involving 25 to 30

• Involving three to five companies

• Usually most companies are repeat contacts

• Students adding value while gaining first hand knowledge.

Using Lean to Develop Partnerships between Students and Industry

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