Explore high-paying careers in clean, high-tech Connecticut manufacturing.

Name of NGM Educator:

David Salonia, Technology Education and Project Lead the Way, Berlin High School, Berlin, CT

Name of Host Company:

Wiremold

Grade Level:

10-11th

Student Work Types:

1. Introduce the concept of Lean Manufacturing and assign Key Questions and vocabulary as homework.
2. Watch presentation on Lean Manufacturing
3. Students will do the activity in teams of 6.
4. Students from the team will do an informal presentation on what they learned as a result of doing the activity.  Also, how does the activity connect with the concepts learned through the slide presentation?
5. Students will attend a trip to Wiremold for a plant tour, showing how they use Lean Manufacturing Concepts to control their product.

Task Abstract:

Lean Manufacturing concepts

Task Objectives:

The task is for a team of students to build a model toy using traditional and then lean manufacturing concepts.  As a result of this lesson, the students will understand why it’s so important for manufacturers to embrace this technology.

Esssential Understandings/Questions:

1.      Traditional manufacturing includes the sales forecast of product demand and production of “batches” of parts before they are transferred to the next operation.  This causes wasted time, quality defects, and excessive in-process inventory which are expensive and difficult to control.

2.      Lean manufacturing involves the creation of products that are made to a customer order.  The customer order starts the production process.  Each part or sub-assembly is made based on demand from the previous operation.  When one part is finished, it is advanced to the next operation to create a “one-piece flow”.

3.     In order for lean manufacturing to work, visual controls are placed in strategic locations so workers know when to produce more parts.

4.     The production of new or existing products can be improved through a brainstorming and process improvement event called a Kaizen.

Task Description:

This activity is designed to show the differences between traditional and lean manufacturing systems.  Students will learn how companies can increase production throughput, minimize losses, and minimize work-in-process inventory using lean manufacturing concepts.  The estimated time to complete this activity is 60 minutes.

Resources Required:

• An assortment of building blocks
• Table 3’ x 6’ or larger for each team
• Whiteboard or score sheet for tabulation of team results
• Thickness gauge (for checking quality of work)
• Containers for demonstrations
• Boxes for tear down during the demonstrations
• Stop watch
• Facilitator instructions
• Work instructions for demonstrations

Prior Learning Required:

There is no prior learning needed outside of the material presented in the lesson.

classroom

Individual or Group Work: 

Students will answer key questions and do a vocabulary crossword prior to the formal lesson and hands-on activity.  Students will watch a slide presentation as a group.  Students will work in teams to assemble a model toy using traditional and lean manufacturing concepts

No special needs other than the materials and supplies previously noted.  Other than the lesson itself, no prior understanding of manufacturing is needed.

Educator Comments:   

I feel this activity will do a good job of introducing lean manufacturing concepts and showing the students how “lean” plays a vital role in manufacturing efficiency.  In summary, the learning activity is interesting and fun, thus encouraging students to possibly consider manufacturing as a career.