Machinery
Course Details
KTO KARATAY UNIVERSITY
Trade and Industry Vocational School
Programme of Machinery
Course Details
Trade and Industry Vocational School
Programme of Machinery
Course Details
| Course Code | Course Name | Year | Period | Semester | T+A+L | Credit | ECTS |
|---|---|---|---|---|---|---|---|
| 08831105 | Lean Manufacturing Technologies | 2026 | Autumn | 3 | 2+1+0 | 5 | 5 |
| Course Type | Elective |
| Course Cycle | Associate (Short Cycle) (TQF-HE: Level 5 / QF-EHEA: Short Cycle / EQF-LLL: Level 5) |
| Course Language | Turkish |
| Methods and Techniques | Lecture, question and answer, discussion, problem-solving, case studies, production process analysis, value stream mapping exercises, group work, case analysis, and practical process improvement activities. |
| Mode of Delivery | Face to Face |
| Prerequisites | There are no prerequisites for this course. Basic knowledge of manufacturing methods and production processes is recommended. |
| Coordinator | Lect. Mehmet AKSOY |
| Instructor(s) | Lect. Muhammed Emin BOYACIOĞLU |
| Instructor Assistant(s) | - |
Course Instructor(s)
| Name and Surname | Room | E-Mail Address | Internal | Meeting Hours |
|---|---|---|---|---|
| Lect. Muhammed Emin BOYACIOĞLU | T-202 | [email protected] | 7671 | Monday 14.00 - 16.00 |
Course Content
Lean manufacturing philosophy and fundamental principles, the seven types of waste, value-added and non-value-added activities, the 5S method, Kaizen and continuous improvement, Value Stream Mapping (VSM), Just-in-Time (JIT) production, SMED, Poka-Yoke, standardized work, visual management, lean quality control, bottleneck analysis in production lines, process performance evaluation, ergonomics and occupational health and safety, lean transformation applications, and productivity improvement methods.
Objectives of the Course
The aim of this course is to introduce students to lean manufacturing philosophy, its fundamental principles, and waste encountered in production processes, and to develop their ability to analyze and improve production processes using lean manufacturing tools and techniques. The course also aims to enable students to evaluate the relationships between productivity, quality, ergonomics, and occupational health and safety in production lines, identify bottlenecks, and develop solutions for continuous improvement.
Contribution of the Course to Field Teaching
| Basic Vocational Courses | X |
| Specialization / Field Courses | |
| Support Courses | |
| Transferable Skills Courses | |
| Humanities, Communication and Management Skills Courses |
Relationships between Course Learning Outcomes and Program Outcomes
| Relationship Levels | ||||
| Lowest | Low | Medium | High | Highest |
| 1 | 2 | 3 | 4 | 5 |
| # | Program Learning Outcomes | Level |
|---|---|---|
| P1 | Acquires fundamental, up-to-date, and practice-oriented knowledge related to the profession and uses it effectively. | 4 |
| P2 | Gains knowledge about occupational health and safety and quality processes. | 5 |
| P4 | Evaluates professional problems and issues independently, using an analytical and critical approach, and proposes solutions. | 5 |
| P13 | Explains quality control methods. | 5 |
Course Learning Outcomes
| Upon the successful completion of this course, students will be able to: | |||
|---|---|---|---|
| No | Learning Outcomes | Outcome Relationship | Measurement Method ** |
| O1 | It explains the lean manufacturing philosophy, its fundamental principles, and the seven basic wastes (Muda) in production processes. | P.1.25 | 1,7 |
| O2 | It defines lean manufacturing tools and techniques such as Value Stream Mapping (VSM), 5S, Kaizen, SMED, Poka-Yoke, and JIT (Just-in-Time). | P.1.26 | 1,7 |
| O3 | It explains the functioning of ergonomics, OHS, and quality processes within lean transformation implementations, as well as their relationship with process improvement. | P.2.2 | 1,7 |
| O4 | Evaluates efficiency and bottleneck issues in production systems using an analytical approach and develops lean solutions. | P.4.22 | 1,7 |
| O5 | It analyzes quality control and standardization processes on production lines using lean tools. | P.13.9 | 1,7 |
| ** Written Exam: 1, Oral Exam: 2, Homework: 3, Lab./Exam: 4, Seminar/Presentation: 5, Term Paper: 6, Application: 7 | |||
Weekly Detailed Course Contents
| Week | Topics |
|---|---|
| 1 | Lean Manufacturing Philosophy, Historical Development, and Fundamental Principles |
| 2 | Value, Value-Added Activities, and the Seven Types of Waste (Muda) in Lean Manufacturing |
| 3 | 5S Yöntemi ve İş Yeri Organizasyonu |
| 4 | Kaizen and the Continuous Improvement Approach |
| 5 | Değer Akış Haritalama (VSM) ve Mevcut Durum Analizi |
| 6 | Future State Design and Process Improvement Using Value Stream Mapping |
| 7 | Just-in-Time (JIT) Production, Pull Systems, and Kanban |
| 8 | SMED Yöntemi ve Kalıp/Ürün Değişim Sürelerinin Azaltılması |
| 9 | Poka-Yoke, Error Prevention, and Quality at the Source |
| 10 | Standardized Work, Visual Management, and Standardization of Production Processes |
| 11 | Quality Control and Continuous Quality Improvement in Lean Manufacturing |
| 12 | Bottleneck Analysis, Work Study, and Productivity Measurement in Production Lines |
| 13 | Ergonomics, Occupational Health, and Safety in Lean Manufacturing |
| 14 | Lean Transformation Applications, Process Improvement Projects, and General Review |
Textbook or Material
| Resources | Lean Manufacturing Guide – Tugay Osmanoğlu, Demiral Akbar (Nobel) |
Evaluation Method and Passing Criteria
| In-Term Studies | Quantity | Percentage |
|---|---|---|
| Attendance | - | - |
| Laboratory | - | - |
| Practice | 1 | 20 (%) |
| Homework | - | - |
| Presentation | - | - |
| Projects | - | - |
| Quiz | - | - |
| Midterms | 1 | 30 (%) |
| Final Exam | 1 | 50 (%) |
| Total | 100 (%) | |
ECTS / Working Load Table
| Quantity | Duration | Total Work Load | |
|---|---|---|---|
| Course Week Number and Time | 14 | 2 | 28 |
| Out-of-Class Study Time (Pre-study, Library, Reinforcement) | 14 | 3 | 42 |
| Midterms | 0 | 0 | 0 |
| Quiz | 10 | 2 | 20 |
| Homework | 0 | 0 | 0 |
| Practice | 14 | 3 | 42 |
| Laboratory | 0 | 0 | 0 |
| Project | 0 | 0 | 0 |
| Workshop | 0 | 0 | 0 |
| Presentation/Seminar Preparation | 0 | 0 | 0 |
| Fieldwork | 0 | 0 | 0 |
| Final Exam | 1 | 16 | 16 |
| Other | 0 | 0 | 0 |
| Total Work Load: | 148 | ||
| Total Work Load / 30 | 4,93 | ||
| Course ECTS Credits: | 5 | ||
Course - Learning Outcomes Matrix
| Relationship Levels | ||||
| Lowest | Low | Medium | High | Highest |
| 1 | 2 | 3 | 4 | 5 |
| # | Learning Outcomes | P1 | P2 | P4 | P13 |
|---|---|---|---|---|---|
| O1 | It explains the lean manufacturing philosophy, its fundamental principles, and the seven basic wastes (Muda) in production processes. | 5 | - | - | - |
| O2 | It defines lean manufacturing tools and techniques such as Value Stream Mapping (VSM), 5S, Kaizen, SMED, Poka-Yoke, and JIT (Just-in-Time). | 4 | - | - | - |
| O3 | It explains the functioning of ergonomics, OHS, and quality processes within lean transformation implementations, as well as their relationship with process improvement. | - | 5 | - | - |
| O4 | Evaluates efficiency and bottleneck issues in production systems using an analytical approach and develops lean solutions. | - | - | 5 | - |
| O5 | It analyzes quality control and standardization processes on production lines using lean tools. | - | - | - | 5 |