1

ISyE 476: Course Overview

Professor Raj VeeramaniRm. 4101 ME Bldg

E-mail: raj@cae.wisc.edu

2

Today’s agenda

• Course objectives, expectations and schedule

• Project execution framework and practical tips

• List of industry projects

• “Overview of VSM” + Group activity– Andy Porter, WMEP

3

Course Objectives

• ISyE 476 is a senior “capstone” design course in which student teams work with business clients on a consulting project.

• The educational objectives of this course are:– To provide hands-on experience with system/process design and

performance improvement projects in a dynamic, complex environment

– To have students synthesize and effectively apply knowledge of ISyE methods, concepts, and tools in all facets of the project lifecycle

– To enhance skills in teamwork, oral and written communication, and project management

4

What you will do in this course• At the beginning of the semester, students receive orientation on the process of

consulting. Students will also be provided a list of potential project opportunities with various local companies.

• Students form their own teams (typically 4 students in each team), and choose the company and project that they want to work on.

• Then, for the next 12 weeks, each student team works with their client to clarify the project goals and scope, define the anticipated deliverables, gather data, conduct analysis and develop solutions. Time permitting, student-teams are encouraged to implement/pilot the solution and assess effectiveness.

• Each member of a student team spends about 8 hours per week on the project for a period of 3 months (February through April). There are no quizzes or exams in this course.

• Student teams develop two interim reports and presentations during the semester as well as a final report and presentation to the class at semester end.

• In addition, each team will provide a weekly status update.

• Each team is expected to meet with the instructor as needed to get guidance on data collection, analysis and solution development.

5

WEEKLY UPDATE

Project Update

DateProject Location and Title:

Project Aim/Goal Statement:

General Project Status:Milestones Completed in

the Past Week: Goals for the Next Week:

Additional Information to

Share (i.e. concerns, needs,

issues):

Team Member Names:

Week of XX/XX/XXXX

Please insert your project location, project title, and Team name (if applicable)

Insert your project's Aim/Goal statement

What are you currently working on?

What have you accomplished in the last week?

What do you plan to accomplish in the next week?

Please provide any additional information you feel is pertinent to your project

Provide the names of your team members

Spring 2013 ISyE 476 PROJECT WEEKLY UPDATE

Please fill out the information below and email to Prof. Raj Veeramani (raj@cae.wisc.edu). Include the project location and title in the subject line of your email. Teams working on project with the UWMF should also Cc the email to Elizabeth Strutz at elizabeth.strutz@uwmf.wisc.edu

Only one response is needed per team, and shaded areas will be identical from one week to the next

6

GradingGrading in the course will be as follows: Interim presentation and report #1: Project Charter – 5% Interim presentation and report #2: Situation Analysis – 15% Final presentation (in-class) – 25% Final report – 35% Company feedback on project – 15% Weekly updates – 5% The Interim presentations and reports will be used to provide feedback and graded on a scale of “Incomplete (0)”, “Unsatisfactory (1)”, Basic (2)”, “Proficient (3)”. Each team will have the opportunity to improve the grade on an Interim report/presentation by fixing deficiencies at the time of submitting the next presentation/report.

7

We will also conduct Peer Evaluation of Team Members at semester end. In this Peer Evaluation, team members will have the opportunity to assess the performance of their team member(s). The instructor will consider this peer evaluation in determining the individual grade for each student on the team.

All students are expected to attend all the class meetings and presentation sessions. If you anticipate missing any class session (e.g., out of town trip for an interview), you need to email me ahead of time to notify me of your intended absence -- Any unexcused absences will impact your grade.

Final Grade

Total Points

A > 93AB > 87B > 80

BC > 75C > 65

8

9

Transportation Policy• Review policy described in course handout

• Public transportation and/or UW Car Fleet cars should be utilized whenever possible. Fleet cars can be reserved through Carol Anne Krueger (Room 3246 of Mechanical Engineering) or Sheryl Hanley (Room 3270), with a minimum of 24 hours notice.

• Students may also elect to use their own vehicles to travel to selected sites. If you select this option, you may be reimbursed for mileage expenses directly related to the course experience, at the lowest applicable state rate.

• Any student who elects to drive to off-campus project sites should register as an approved driver. Note that any travel prior to receiving this approval may not be reimbursed!

• Take attached Driver Authorization Form to get ISyE Dept signature (Sheryl Hanley – Room 3270) and submit for UW approval. (Some individuals may need to get notary signature as well – See policy).

10

Date In-Class Activity Out-of-Class Activity

1/22/2013Course overview; Project execution framework and practical tips;Overview of Value Stream Mapping

Identify your team members (4 students per team typically)Inform Professor Veeramani which project your teams wants to work on; First come, first served.

1/29/2013Project teams and projects confirmed.In-class workshop on Lean concepts

Contact company to schedule kick-off mtg (Target week of Feb 4); Research the company's website and prepare for the kick-off mtg.

2/5/2013 In-class workshop on 5S and facility design Project kick-off meeting at the company; Develop project plan

2/12/2013 No classFinalize Project Charter and project plan with company and initiate information/data collection efforts

2/19/2013 No classPrepare Interim Report #1 and presentation; Project work to map and analyze current state, document improvement opportunities and challenges, identify root causes and gaps

2/26/2013Presentation and Report #1: Project Charter (including Project goal, proposed approach and planned activities)

Project work to map and analyze current state, document improvement opportunities and challenges, identify root causes and gaps

3/5/2013 No classProject work to map and analyze current state, document improvement opportunities and challenges, identify root causes and gaps

3/12/2013 No class Prepare Report #2 and presentation; Project work to develop ideas for alternate solutions

3/19/2013Presentation and Report #2: Situation Analysis (including Current state assessment, opportunities for improvement or Design requirements)

Project work to design and analyze alternate solutions

3/26/2013 Spring Break

11

3/26/2013 Spring Break

4/2/2013 No class Project work to design and analyze alternate solutions

4/9/2013 No class Project work for evaluation of alternate solutions; Prepare Report #3 and presentation

4/16/2013Team meeting with Prof. Veeramani to discuss recommendations, implementation plan, business case.

Project work to develop recommendations, implementation plan and business case

4/23/2013 No classProject work to finalize recommendations, implementation plan and business case; Pilot implementation if possible. Develop final presentation and report

4/30/2013 Final in-class presentations; Final presentation at company to be completed between May 8 and May 19 Final presentation and report

5/7/2013 Final in-class presentations; Final presentation at company to be completed between May 8 and May 19 Final presentation and report

5/19/2013 Final report due; Client project feedback form duePeer Evaluation due

Upload the final report and presentation to the dropbox

12

Today’s agenda

• Course objectives, expectations and schedule

• Project execution framework and practical tips

• List of industry projects

• “Overview of VSM” + Group activity– Andy Porter, WMEP

13

Types of Projects

• Improve an existing procedure, process, or system.– Waste and inefficiencies are common.– Improve quality and productivity

• Develop a new procedure, process, or system.– No standardized methods are followed.– New business requirements/needs are to be met.

14Source: Joey Valdez

15

Project Framework

I. Define and Analyze1) Pre-visit prep2) Orientation and Kickoff3) Problem statement & scope4) Diagnostics – Root-cause analysis; Requirements; Gaps

II. Design and Evaluate5) Solution generation and design6) Solution evaluation, prioritization and testing

III. Deploy and Sustain7) Solution implementation planning and execution8) Sustaining the change

What must we do to succeed?

• Understand the problem from the viewpoint of the business

• Establish a scope of the problem

• Understand the impacts of the problem

• Establish credibility

• Draw insights from data collected

• Recommend Solutions which solve the problem and create impact

• Make a connection with the client

Understand the Problem

• Ask questions to clarify the problem– How long has this been going on?– Is it consistent or intermittent?– Is it apparent across multiple product, shifts, areas?– Which metrics are affected by this problem?

• How much? And what is that worth?

• Listen actively and take notes– Summarize to confirm you understand correctly

• Identify Next Steps– Don’t leave without agreement on what will happen next. – If you will be meeting again, schedule the date & time

• Thank your client for their time

Establish Scope

• Determine the boundaries of the problem and stay within them– Often People issues are considered out-of-bounds– Which areas/production lines are included or

excluded?– Which products are included or excluded?– Are there any sacred cows? Any areas which the

organization won’t consider changing?

• Scope Creep is the #1 reason for projects going off-track. – Remember to promise less and deliver more.

Understand the Problem Impacts

• Every organization has more problems than you have time to solve. – Focus on the problems that matter

• So which problems matter?– Problems that if solved, will increase sales, increase

capacity, increase capability, reduce cost, improve quality, ….

• To understand the impact of a problem you’ll need to help the client to estimate value– Don’t estimate for the client, estimate with him/her– E.g. “so if you increase capacity 50% how much added revenue

can you expect gain from the added capacity?”

Establish Credibility

• At some point you’ll need to establish credibility as having a valuable skill

• What experience do you have in the area?– Education, or – Industry Experience, or – Technical Experience– Related Experience outside of industry

• Speak about team experience rather than each person’s experience

• Unless you’re asked, offer only a sentence or two on experience.

What experience do you have?

Draw Insights from the Data

• Collect data to better understand the problem

– Verify existence of the problem and the magnitude of the impact

– Establish a baseline level for the impact

• Analyze data to gain insight

– Apply analysis techniques, e.g. value stream mapping, process mapping, is/is not analysis, …

– Learn something from the data; look for insight• What do you see that perhaps the client hasn’t seen?

• Consider possible solutions

Recommend Solutions

• Recommend Solutions which solve the problem and create impact– Identify data or analysis results which support the solution– Draw a connection between the solution and the problem– Estimate impact of the solution (how much $ is it worth?)

• Create solution alternatives– Chevy?, Cadillac?, Do nothing?– Estimate $ impact for each

• Establish ROI– Return (“R”) is $ impact of solution;– Investment (“I”) is your fee (your time & effort)– Make sure “R” is far, far larger than “I”

• Make the decision to proceed a “no-brainer”

ROI

23

Essential considerations for every project

People/Organization

Technology/Systems

Process

Business strategy

alignmentBusiness case

Change management

Connect with your client

1. Understand the Individual; Ask for feedback

2. Keep Commitments; Consistency is the key to trust

3. Clarify and Manage Expectations

4. Attend to little things; Provide Genuine service

5. Show Integrity; Actions aligned with the message

6. Apologize sincerely when you make a mistake

Janessa Lantz, “Company, Customer, and the Emotional Bank Account”, Nov. 29, 2012

In Summary

• Understand the problem from the viewpoint of the business

• Establish the scope of the problem

• Understand the impacts of the problem

• Establish credibility

• Draw insights from data collected

• Recommend Solutions which solve the problem and create impact

• Connect with the client

Today’s agenda

• Course objectives, expectations and schedule

• Project execution framework and practical tips

• List of industry projects

• “Overview of VSM” + Group activity– Andy Porter, WMEP

26

27

List of Project Sponsors1. Madison-Kipp Corporation

2. Berntsen Brass & Aluminum Foundry

3. Uniek, Inc.

4. Dane Manufacturing

5. Springs Window Fashions (3 projects)

6. Stoughton Trailers

7. Research Products

8. UW Hospital and Clinics (6 projects)

Team Formation Assignment1) Form your team (4 students)

– Discuss course schedule to ensure that you have common free-time for making company visits (at least 4 hours to 8 hours each week at company)

– Discuss plan for transportation to company (Use personal vehicle of a team member or UW Car Fleet or Public transportation?)

2) Decide on type of industry project (manufacturing, healthcare or service industry) and your preference for specific company projects.

3) E-Mail (by next Tuesday) Professor Veeramani the names of team members, who is the team spokesperson, and your team’s company project preference from list (1st, 2nd, 3rd preference). – Projects from list will be assigned first-come-first-served. – Your team is also welcome to find your own project.

Incomplete teams and students who have not yet found a team will be matched next Tuesday.

28

Today’s agenda

• Course objectives, expectations and schedule

• Project execution framework and practical tips

• List of industry projects

• “Overview of VSM” + Group activity– Andy Porter, WMEP

29