Manufacturing Systems is critical to the optimal delivery of product and services. This module will cover Lean Operations, Six Sigma, Supply Chain Management and Production Planning, as well as an overview of manufacturing technologies and systems (both current and emerging) used in a range of sectors including: Pharmaceutical & Medical devices; Semiconductor & Nanotechnology.
Lean Production Techniques
History; aliases; main aim; Lean’s definition of waste; adding value; Sea of Inventory analogy; leadtime and WIP reduction; small batch manufacture; push vs. pull production and Kanban; Poka Yoke; Jidoka; 5S; SMED; Kaizen; Cellular Manfuacturing; Standard Work; Visual Managment; Supplier Relationships and Quality in a Lean environment.
Six Sigma
History. Variation and normal distribution, short-term and long-term sigma. The principles of Six Sigma; The Process Equation; Lean vs. Six Sigma; Roles within Six Sigma programs; the DMAIC model (Define, Measure, Analyse, Improve, Control); some Six Sigma tools used at each stage of DMAIC, including some of the following: Project Charters, Voice of the customer (VOC), SIPOC, CTQ, Cause & Effect Diagrams, 5 Why's, Process mapping etc.
Supply Chain Management (SCM)
What is a Supply Chain, and SCM; complexity and uncertainty in SCM; why are companies using SCM; The Bullwhip Effect; Information Technology – the SCM enabler – e-business, EDI, RFID, bar-codes, internet, build-to-order; Supply Chain integration; different Supplier relationships.
Capacity Management & Production Planning
Different Capacity Management strategies (Chase demand, Level Production, Excess Capacity etc.) and advantages/disadvantages of each; The hierarchical nature of the production planning process: aggregate planning, master production scheduling (MPS), rough cut capacity planning, final assembly schedule. Developing these in practice using spreadsheets.
Emerging Manufacturing Technologies & Innovation:
Technology development, adoption, evolution and systems analysis.Invention vs innovation: Patents and Patent Analysis.Definition of Innovation, types and theories of innovation, sources of innovation and management of innovation.
Semiconductor & Nanotechnology
Process sequence used to fabricate an integrated circuit/ MOS capacitor. Oxidation: Dry and wet oxidation. Vacuum technology. Metal deposition: Evaporation, magnetron and RF sputtering. Photolithography: Masks, mask alignment. UV, xray and electron beam lithography. Etching: Wet etching and dry etching. Diffusion: Fick's laws. Sheet resistance and four pointprobe. Cleanroom lab based on semiconductor technology.
Pharma & Medical Devices
Unit Operations & Equipment: Batch versus continuous processing, Process Analytical Technology (PAT): Multivariate data acquisition and analysis tools; Modern process analyzers or process analytical chemistry tools; Process and endpoint monitoring and control tools. Formulation & Tablet Production, Active Drug Ingredient and tablet excipients; Production steps for a tablet process: pre-formulation, formulation, milling, blending, drying, granulating, tableting, coating. The role of GMP.Medical Devices: the technologies and systems issues. FDA certification.
| Module Content & Assessment | |
|---|---|
| Assessment Breakdown | % |
| Other Assessment(s) | 100 |