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Advance Lean Practitioner (ALP) School of Mechanical Engineering

The Advance Lean Practitioner (ALP) program is offered by the School of Mechanical Engineering. The program consists of several modules designed to equip students with the knowledge and skills necessary to become lean leaders.

List of ALP Modules

The ALP program comprises the following modules:

• Module 1: Value Stream Mapping
• Module 2: Pull System Simulation (boNKI) and Production Capacity
• Module 3: Flexible Cell and Sequence Combination
• Module 4: Training Method and Heijunka
• Module 5: Enabling Single Minute Die Exchange (SMED) and Lean Metrics
• Module 6: Total Productive Maintenance and Quality at the Sources
• Module 7: Gemba Walk and Scrum

Overview of ALP Modules

Module 1 - Value Stream Mapping

This module teaches students how to develop Value Stream Mapping (VSM). The process begins with the supplier and ends with the client, focusing on removing waste throughout the manufacturing process flow. Students participate in an exercise known as 'Michigan Steel Current State Mapping' to sketch, debate, and re-edit the current state mapping and obtain the future state mapping.

Module 2 - Pull System Simulation (boNKI) and Production Capacity

The pull system module is taught through simulation games using Kanban cards to fetch resources from the warehouse, producing items based on client orders to decrease inventory and waste. A production capacity worksheet is introduced to evaluate the process flow in production, recording details of each process. The information obtained is used to allocate work to workers in a cell using the Sequence Combination Table.

Module 3 - Flexible Cell and Sequence Combination

This module focuses on Shojinka, which means altering the number of workers at a cell when production demand changes. Students learn to prepare production with a flexible work cell, ensuring smooth production without interruptions. The module discusses four key factors to achieve flexible capacity: improving work instructions, using lean tools, increasing multi-skilled operators, and visualizing Takt time and cell status.

Module 4 - Training Method and Heijunka

Students learn about training methods, including the Socratic method and 4-step method. An activity using a thinker bell is conducted to train participants in removing a ring according to a pre-set Takt time. The module also covers Heijunka or workload leveling, where students understand the importance of making decisions in production lines with fluctuating demand.

Module 5 - Enabling Single Minute Die Exchange (SMED) and Lean Metrics

This module teaches students to implement SMED through an activity using a racing car, where spare parts need to be changed, and changeover time is recorded and improved. The module also introduces lean metrics, including Labour Minutes Per Unit (LMPU), First Pass Yield (FPY)%, Rolled Throughput Yield (RTY)%, Parts Per Million (PPM), Production Efficiency (PEFF), and Shipping Efficiency (SEFF).

Module 6 - Total Productive Maintenance and Quality at the Sources

A properly implemented Total Productive Maintenance System (TPM) provides stability for lean production. Students participate in an activity checking the abnormality of a bicycle and trying to fix the problems. They are also taught to predict failure using methods like temperature checks and ultrasonic leak detection. The module focuses on quality methods, incorporating tools and methodologies into the culture, such as Jidoka, QFD, FMEA, Control Plan, Poka Yoke, etc.

Module 7 - Gemba Walk and Scrum

This module helps students recognize Lean principles applied in Scrum and obtain hands-on practice in the Scrum process. A hands-on activity allows students to design a Golf Resort brochure, applying Scrum methodology to advertise and promote the resort.

School of Mechanical Engineering

The School of Mechanical Engineering is located at the Engineering Campus, Universiti Sains Malaysia, 14300, Nibong Tebal, Pulau Pinang.