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Using Lean to Develop
Partnerships between Students
and Industry
Dr. Jim Keyes
College of Management
Inspiring Innovation....
UW Stout
Wisconsin’s Polytechnic University
Mission:
University of Wisconsin-Stout is a career-focused,
comprehensive poly...
UW Stout Facts
• Enrollment
• 9,371 fall 2014
• 88% Undergraduate
• 12% Graduate
• Programs
• 44 Undergraduate
• 20 Gradua...
College of Management
Departments
• School of Hospitality
• Business
• Operations and
Management
• Military Science
Underg...
Lean:
The process of doing more with less
• Broader range of goods
• Fewer inputs – more outputs
• Lower costs
• Higher qu...
Value of Lean Before..
@ACBSPAccredited #ACBSP2015
Value of Lean Since…
@ACBSPAccredited #ACBSP2015
Need for Lean Training
• 2003 survey by DemandStream 280 manufacturers
• 40% of U.S. manufacturers use Lean as their prima...
Need for Lean Training
• Monster.com indicated 975 “lean” positions
posted in October of 2006
• The same search recently i...
Lean Enterprise Institute
• Working to implement Lean education in
academic settings
• LEAN – Lean Education Academic Netw...
Applications of Lean
• Presently dominated by manufacturing, by large
producers
• New Users
• Small shop manufacturers
• S...
Student Audience for Lean
Training
• Technology
• Engineering
• Business
• Supply Chain
@ACBSPAccredited #ACBSP2015
Course Development
• Utilizing the Lean training that employers
presently find value in to scope the lean course.
• Five P...
Course Outline
• Definitions - Vocabulary
• Methodologies
• Standardization
• Culture
• Empowerment
• Visual control
• App...
Using Lean to Partner with
Industry
• Industry is using lean tools
• Students are learning lean
• The Polytechnic approach...
Course Outline
Divided between the Classroom
five weeks instruction, demonstrations and readings
nine weeks of application...
Projects begin with an A3 Report
• Standardized storytelling
• Not solving the problem
• Identifying the issues
• A plan t...
Industry Project Examples
• Actual student projects from the past
few years
• Major and small corporation
• Large and smal...
Results from New Layout
Steps Set Up Final
Initial Steps 50 134
Steps After
Changes Made 32 73
% Reduction 36% 46%
Test Wa...
Refill Line
• Suggestion: Add a refill line to
each bin.
• Benefit: Adding a refill line
will alert workers when
hardware ...
Pulley Assembly
• Total Non-value Added time = 13 + 6 + 7 + 90 + 4 = 120 seconds = 2 minutes
• This time is wasted with ea...
Typical Semester Corporate
Projects
@ACBSPAccredited #ACBSP2015
• Five to six projects involving 25 to 30
• Involving thre...
Using Lean to Develop Partnerships
between Students and Industry
Questions / Comments
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Using Lean to Develop a Partnership Between Students and Industry

Partnering with industry has provided students with a real-world laboratory experiences. Companies varying from manufacturing to service operations have allowed students access to their operations to work directly with their employees to implement lean process improvements.

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Using Lean to Develop a Partnership Between Students and Industry

  1. 1. Using Lean to Develop Partnerships between Students and Industry Dr. Jim Keyes College of Management Inspiring Innovation. Learn more at www.uwstout.edu
  2. 2. 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 #ACBSP2015Dr. Jim Keyes College of Management Inspiring Innovation.
  3. 3. 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 #ACBSP2015Dr. Jim Keyes College of Management Inspiring Innovation.
  4. 4. 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
  5. 5. 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 @ACBSPAccredited #ACBSP2015
  6. 6. Value of Lean Before.. @ACBSPAccredited #ACBSP2015
  7. 7. Value of Lean Since… @ACBSPAccredited #ACBSP2015
  8. 8. 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
  9. 9. 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 @ACBSPAccredited #ACBSP2015
  10. 10. 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 @ACBSPAccredited #ACBSP2015
  11. 11. Applications of Lean • Presently dominated by manufacturing, by large producers • New Users • Small shop manufacturers • Service industries • Back-office • Sourcing • Logistics • Retail • Healthcare @ACBSPAccredited #ACBSP2015
  12. 12. Student Audience for Lean Training • Technology • Engineering • Business • Supply Chain @ACBSPAccredited #ACBSP2015
  13. 13. 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 @ACBSPAccredited #ACBSP2015
  14. 14. Course Outline • Definitions - Vocabulary • Methodologies • Standardization • Culture • Empowerment • Visual control • Application @ACBSPAccredited #ACBSP2015
  15. 15. 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
  16. 16. 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 @ACBSPAccredited #ACBSP2015
  17. 17. 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 @ACBSPAccredited #ACBSP2015
  18. 18. 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 @ACBSPAccredited #ACBSP2015
  19. 19. Results from New Layout Steps Set Up Final Initial Steps 50 134 Steps 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 EstimatedAmountof Steps
  20. 20. 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
  21. 21. 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
  22. 22. Typical Semester Corporate Projects @ACBSPAccredited #ACBSP2015 • 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.
  23. 23. Using Lean to Develop Partnerships between Students and Industry Questions / Comments

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