Summary Unit 39 - Modern Manufacturing Systems Assignment 3 - Distinction Grade
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Unit 39 - Modern Manufacturing Systems
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BTEC National Engineering
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Unit 39 - Modern Manufacturing Systems
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BTEC Assignment Brief
Pearson BTEC Level 3 National Diploma in Engineering
Pearson BTEC Level 3 National Diploma in Manufacturing
Engineering
Qualification Pearson BTEC Level 3 National Extended Diploma in
Engineering
Pearson BTEC Level 3 National Extended Diploma in
Manufacturing Engineering
Unit number and title Unit 39: Modern Manufacturing Systems
Learning aim(s) (For NQF C: Investigate the principles of Lean manufacturing and
only) how these influence productivity
The potential advantages of adopting the Lean philosophy
Assignment title
Brent Marshall
Assessor
w/c 20/01/23
Issue date
w/c 06/02/23
Hand in deadline
, You have recently started an apprenticeship with a small
manufacturing company. Your supervisor has read your CV
and noticed that one of the units that you studied in your
BTEC programme at school covered the principles and
methods/tools associated with Lean. This is something that
the Operations Director has talked about in the past as a
way of improving the productivity and responsiveness of
your company. Your supervisor is keen to find out more
about Lean and how it might be applied in practice on the
shop floor in your factory.
The company’s order books are full due to securing a large
order for the manufacture of specialist bolts from a
construction company involved in a large civil engineering
project. Order details for manufacture are shown in the
table below (Fig 1).
Vocational Scenario or Simulations of the manufacture of the parts has delivered
Context the manufacturing times shown in Fig 2.
PRODUCT CODE PRODUCT NAME TURNING OPERATION TIME M/C LOAD/UNLOAD TIME MILLING OPERATION TIME M/C LOAD/UNLOAD TIME TOTAL TIME
CAM40 -001 M12X1.8 BOLT 2M 18S 25S 4M 10S 2M 15S 9M 8S
CAM40 -002 M24X3.0 BOLT 2M 34S 25S 13M 12S 2M 15S 18M 26S
CAM40 -003 M36X4.0 BOLT 5M 29S 25S 15M 34S 2M 15S 23M 43S
CAM40 -004 M44X4.5 BOLT 5M 35S 25S 21M 4S 2M 15S 29M 19S
CAM40 -005 M50X5.0 BOLT 7M 40S 25S 22M 22S 2M 15S 32M 42S
Fig 2 Manufacturing times
On the pre-production simulations there have been a
number of quality issues with the finished parts including:
• Poor quality screw threads (torn)
• Incorrect turned diameters
• Incorrect depth on bolt head slots
In addition to these issues it has been logged that a lot of
time is lost moving the parts through the production
process i.e.. material collection, turned features, milled
features, inspection, despatch.
Due to your previous study of Lean Manufacturing, the
Operations Director has asked you to investigate the
implementation of lean manufacturing, set-up a lean
simulation and present this to the Operations Director. The
aim of the simulation is to reduce/eliminate the
, manufacturing quality issues and lost time through
unnecessary movement through the production process.
Set-up a lean simulation (or simulations) based on an
element of a manufacturing environment and record
evidence of:
● The details of the problem(s) it is designed to
eliminate
● The expected outcome of the simulation(s)
● How the simulation(s) will be set up and controlled
● How a range of at least three Lean tools and/or
methods will be applied to the simulation(s)
● The actual outcome obtained
Your presentation should then provide detailed information
on:
● The key characteristics of (for example, short lead
times, minimum work-in-progress, defect elimination
etc) and reasons for (for example, eliminating waste,
improving quality, increasing flexibility etc) adopting
Lean principles in a manufacturing environment, and
the requirements needed to implement it
successfully (for example, a team approach,
Task 1 continuous improvement, dependable suppliers etc)
● How Lean principles would be implemented in
practice by employing the three Lean tools/methods
used in the above simulation(s) (for example, by
using Kanban, Bottleneck analysis, 5S etc); specify
the problem that each Lean tool/method is designed
to eliminate, the methodology involved in the use of
each Lean tool and their expected impact on the
processes involved with reference to the principles of
Lean operations
● The simulations(s) undertaken, including the details
of the problem(s) it was designed to eliminate, the
expected outcome of the simulation(s), how the
simulation(s) was set up and controlled, how a range
of at least three Lean tools and/or methods were
applied to the simulation(s) and the actual outcomes
obtained
● How effective the three Lean tools and/or methods
are in helping to achieve the key characteristics of
Lean operations, with reference to the outcomes of
the simulation(s) undertaken
● Which of the three Lean tools/methods make the
most effective contribution to supporting the key
characteristics of Lean.
3
BTEC Assignment Brief v1.0
BTEC Internal Assessment QDAM January 2015
,Checklist of evidence ● Annotated photographs/video with commentary
required showing the lean manufacturing simulation(s) being
carried out
● A tutor observation record confirming the
manufacturing simulation(s) was carried out by the
learner
● A printed copy of the presentation (with embedded
images/video) including presenter notes
Criteria covered by this task:
Unit/Criteria
To achieve the criteria you must show that you are able to:
reference
Explain the key characteristics of Lean and the requirements needed to
39/C.P5
implement it successfully
39/C.P6 Explain how at least one Lean tool and/or method can be applied.
Demonstrate effectively at least one of the key Lean tools, using a
39/C.P7
manufacturing simulation
Analyse how a range of Lean tools and/or methods relate back to the
39/C.M3
key characteristics of Lean simulation
Demonstrate effectively a range of the key Lean tools and/or methods
39/C.M4
using a manufacturing simulation
Evaluate how a range of Lean tools and/or methods relate back to the
39/C.D3 key characteristics of Lean including the effectiveness of a Lean
manufacturing simulation
Sources of information Books
to support you with Slack, Nigel, Alistair Brandon-Jones, and Robert Johnston.
this Assignment 2012. Operations Management. 7th ed. Harlow: Financial
Times Prentice Hall.
ISBN 9780273776208
Liker, Jeffrey K. 2004. The Toyota Way. 2nd ed. New York:
McGraw-Hill.
ISBN 9780071392310
Dennis, Pascal. 2007. Lean Production Simplified: A Plain
Language Guide To The World's Most Powerful Production
System. 2nd Ed. Productivity Press.
ISBN 9781563273568
Websites
Toyota. 2016. Toyota Production System. [Online].
Available from: http://www.toyota-
global.com/company/vision_philosophy/toyota_production_
system/
Lean Simulations. 2012. List of Lean Games and
Simulations. [Online]. Available from:
http://www.leansimulations.org/p/huge-list-of-free-lean-
games.html
4
BTEC Assignment Brief v1.0
BTEC Internal Assessment QDAM January 2015
, Lean Simulations. 2011. Seven Benefits of Teaching Lean
with Simulations. [Online]. Available from:
http://www.leansimulations.org/2011/01/seven-benefits-of-
teaching-lean-with.html
Lean Games. 2016. Lean Games website. [Online].
Available from: http://www.leangames.co.uk
Above are some examples of websites. Further useful
resources may be found at
http://qualifications.pearson.com/en/support/published-
resources.html#step1
Other assessment
materials attached to
this Assignment Brief
,Investigate the principles of Lean
manufacturing and how these influence
productivity
, The following information is included in this presentation based on the key requirement
• In this presentation I will talk about the key characteristics of
different lean tools and how they function within an engineering
business.
• I will further develop on this by carrying out a thorough
explanation on how will it improve and prevent existing issues
within the organization.
• Based on the lean tools used a new and improved workshop
layout is made and a detailed simulation is undertaken to ensure
full understanding of the issues with the existing layout and how
will the new layout improve those issues.
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