CODE 90455 ACADEMIC YEAR 2024/2025 CREDITS 6 cfu anno 2 INGEGNERIA MECCANICA - PROGETTAZIONE E PRODUZIONE 9269 (LM-33) - GENOVA 6 cfu anno 1 SAFETY ENGINEERING FOR TRANSPORT, LOGISTICS AND PRODUCTION 10377 (LM-26) - GENOVA SCIENTIFIC DISCIPLINARY SECTOR ING-IND/17 LANGUAGE English TEACHING LOCATION GENOVA SEMESTER 1° Semester MODULES Questo insegnamento è un modulo di: PRODUCTION AND TRANSPORT SAFETY ENGINEERING TEACHING MATERIALS AULAWEB AIMS AND CONTENT LEARNING OUTCOMES The course is aimed at studying various aspects of safety and security in industrial applications including: chemical plants, oil & gas, dangerous goods handling etc. Starting from reliability analysis, through Bayesian statistics, reliability modelling and simulation, failure analysis the course will guide the identification of possible risk factors and will presents the most promising methodological approaches. Two practical assignment will be given focusing on industrial incidents involving chemical spills and complex plants failures. AIMS AND LEARNING OUTCOMES The course aims to deliver the following learning objectives: The understanding of the importance and challenges of production principles. (L1) Developed an appreciation for the major methods and techniques in production management. (L2) Acquired analytical capability to uncover problems and improvement opportunities in operations management and recommend improvement along the dimensions of efficiency, quality and speed, and improved teamwork capability to cooperate with others to solve business operations problems. (L3) Analysis of coordination of production decisions between different functions within the business as well as between functions outside, such as suppliers and customers. (L4) Understanding the importance of safety and health, fundamental concepts and terms. (L5) Acquire risk management skills. (L6) TEACHING METHODS The course would utilize various tools- Books, Journal Papers, Popular Readings, Case Studies and Simulations. The classroom session would involve a discussion of the critical concepts, case study discussions and quantitative simulations. This would be supplemented with assignments and exams. Extra readings and cases will be provided separately by the instructor. Instructions will be given in class on preparation before and after each session. The examinations will be based on class discussions, cases and quantitative decision-making based on simulated scenarios. The instructors will follow participative methods in the class. The instruction will predominantly be through interactive lectures and case discussions. The students are expected to come prepared to the class whenever a case or a reading is prescribed. The instructors can call upon any student for his/ her comments (cold call) during the case discussions. The students will be required to learn Excel to explore case simulation, develop strategies and prove the effectiveness of their recommended decisions. No programming language prior knowledge is required for the use of the software. Learning Through Case Method: Effective learning through the case method requires four stages of learning (individual preparation, group discussion, class discussion, and after-class reflection). To make the best use of the learning opportunity following steps may be followed: It would be necessary for you to prepare each day'sday's case/ learning material individually and then discuss it in your group. It is strongly suggested that the reading(s) assigned should be read before preparing for the case. The responsibility could be shared by the members of the group. However, the gist of the readings needs to be understood by each participant. To ensure participation by the students, the instructors may ask the assigned groups to submit case study solutions before the class, and the group may be called upon to make a group presentation. The lead questions for all the cases will be shared by the instructors well in advance. To make the best use of the learning opportunities, the following steps may be followed: Each participant must participate and be ready to share his/ her analysis in the class to build the skills of presentation and the attitude of collective learning. Individual participants/ Groups are encouraged to make presentations of their analysis/ recommendation of the case/ reading material. It would be necessary for you to prepare each day'sday's case/chapter/paper reading individually be prepared with specific recommendations/conclusions and the rationale thereof. If required, the group will be asked to make a one-page synopsis of each case containing the Major issues Analysis for resolving the issue(s) Recommendations/inferences on the major issues The primary purpose of the synopsis is to prepare you for participation in the class. You may also be asked to submit the synopsis at the beginning of the class. You are welcome to discuss and clarify any doubts with the instructor. Laboratories: The course will use mostly Excel, AnyLogic, and AnyLogistiX in these students should be able to do the following: Think critically, be able to identify, generalize, prioritize, isolate, and reduce complexity in dynamic/uncertain and ambiguous operational situations, Understand how strategic considerations influence operational decisions, Apply analysis and improvement tools learned in previous courses to actual business situations, Reason quantitatively and qualitatively to make operational decisions. The laboratory-based case method requires students to prepare a decision, to the extent available, based on careful evaluation of case facts and numbers. As with all business situations, there may be insufficient facts, ambiguous goals, and strong dynamic/uncertain environments. Students, finally, will develop the following skills: Analytical Skills: Students will possess the analytical and critical thinking skills to evaluate issues faced in business and professional careers. Technical Skills: Students will possess the necessary technological skills to analyze problems, develop solutions, and convey information using Excel, AnyLogic, and AnyLogistiX software. SYLLABUS/CONTENT Course Outline: Session/Topic/Reading Material/Reference Session Topics Learning Outcomes Readings and Cases 1-2 Introduction to Operations Management: The Nature of Production Operations Definition of existing operations, operational activities, the experience economy and two views of organizations Reading: Chapter 1 from Textbook [OM]. 3 Case Study 1: Taracare, Inc. CASE Chapter 1: Taracare, Inc. 4-5 Strategy, Operations and Global Competitiveness In these lectures, we define operations management as the activities associated with transforming inputs into valued outputs. The actual production system is defined in terms of its environment, inputs, transformation system, outputs, and the mechanism used for monitoring and control. We continue with a definition of customer value as perceived benefits divided by costs. Customer costs include upfront monetary investment, other lifecycle costs for maintenance, and the hassles involved in obtaining the product or service. Discussing customer benefits focuses on innovative products and services, functionality, quality, customization, and responsiveness. The last part discusses productivity as a critical measure to assess the performance of the value-creating process. The discussion of productivity includes alternative productivity measures, including single-factor, multifactor, and total-factor productivity measures. Reading: Chapter 2 from Textbook [OM]. 6 Case Study 2: Izmir National University (INU) CASE Chapter 2: Izmir National University (INU) 7-8 Process Planning and Design We will discuss issues related to Product and Process Planning, beginning with an overview of product design, including discussions of the stages of product development and the product mortality curve. Continuing with selecting an appropriate transformation system, we will focus on describing the primary transformation system forms, the bases for determining between them, and the layout of these transformation forms. Reading: Chapter 3 from Textbook [OM]. 9 Case study 3 X-Opoly Inc. CASE Chapter 3: X-Opoly Inc. 10-11 Six Sigma for Process and Quality Improvement These lectures focus on redesigning and continuously improving business processes in support of the overall business strategy. To put our discussion in perspective, we begin with an overview of three alternative approaches for process improvement. We then turn our attention to the first process improvement strategy, Business Process Design. This is followed by a detailed discussion of the second process improvement strategy, Six Sigma. Next, each phase in Six Sigma'sSigma's DMAIC approach is discussed in more detail, including illustrating the use of representative Six Sigma tools in each stage. The lectures conclude with discussing the various roles associated with Six Sigma, becoming certified, and the need for organizations to customize their approach to Six Sigma training and implementation. Reading: Chapter 4 from Textbook [OM]. 12 Case study 4 Valley County Medical Clinic CASE #4: Excel-based model provided by the teacher 13 Schedule Management The course adds the dimension of time to the previously static picture of the organization. Following this, we consider issues related to efficiently using the available capacity through effective schedule management. The lecture concludes with the discussion of scheduling topic of yield/revenue management and overbooking Reading: Chapter 6 from Textbook [OM]. 14 Inventory Management Excess inventory incurs an extra cost, while insufficient inventories can ruin the schedule, hurting both the strategic value elements of delivery and speed. The lecture discusses the functions and forms of inventory, inventory-related costs, and types of inventory management systems. Reading: Chapter 8 from Textbook [OM]. 15 Enterprise Resource Planning Enterprise resource planning (ERP) systems are the latest innovation in the evolution of systems for coordinating production decisions between different functions within the firm, as well as across functions outside the firm, such as those of suppliers and customers. However, the first step in this evolution started with material requirements planning (MRP) systems. As opposed to inventory management, which concerns items whose demand is independent of other items, MRP is used for dependent demand items. The lecture explains how MRP systems work, their required inputs, and their delivery outputs. Following this, the extensions to material requirements planning are discussed, including distribution requirements planning (DRP), manufacturing resource planning items that are used to create finished products (MRP II), and enterprise resource planning (ERP). Reading: Chapter 9 from Textbook [OM]. 16 The Importance of Safety and Health. Fundamental concepts and terms This lecture discusses core industrial safety issues, particularly why attention must be paid to safety and health from various perspectives, what databases exist to help young engineers, some standard documents, and fundamental concepts and terminology. Reading: Chapter 1,3 from Textbook [SHE] 17 General principles of hazard Control. Mechanics and Structures This lecture aims to lay a foundation for discussing many kinds of hazards and their control. The foundation involves understanding what a hazard is, how to recognize it and how to choose the controls that prevent incidents and accidents and any harm that may result. Reading: Chapter 9,10 from Textbook [SHE] 18 Electrical safety. Tools and Machines. Materials handling. As with all forms of energy, electricity has specific hazards. The goal is to eliminate or control these hazards. This lecture does not cover advanced electrical systems involving three-phase conductor systems, typically with 220 and higher volts. Reading: Chapters 12,13,15 from Textbook [SHE] 19 Fire protection and prevention. Heat and Cold. Ventilation. Personal Protective Equipment. This lecture focuses on the causes of fires, the physics and chemistry of fire, and its behaviour. It also covers the fire safety of buildings and the spread and stopping of fire. However, deaths and injuries during a fire are not only related to the combustion itself but also to high or low temperatures. To create the proper thermal regime, it is necessary to ensure the ergonomics of the workplace, which is also complemented by the ventilation system Reading: Chapters 16,18,25,28 from Textbook [SHE] 20 Risk, Risk Assessment and Risk Management In safety and health, the risk usually infers the probability or likelihood of an adverse event and the severity of the event’s consequences. There are two aspects: frequency and severity. The purpose of this lecture is to identify the concept of risk and the factors contributing to increased risk and to consider various methods of risk assessment Reading: Chapter 34 from Textbook [SHE] RECOMMENDED READING/BIBLIOGRAPHY Course Reading Material: Specific readings and case studies are to be distributed by the Program Office/ Library. Textbook: Meredith, Jack R., and Scott M. Shafer. Operations Management MBAs. John Wiley & Sons, 2023. [OM] Brauer, Roger L. Safety and health for engineers. John Wiley & Sons, 2022. [SHE] References: Buffa, Elwood. "S. and Sarin, Rakesh K, " "Modern Production/ Operations Management, EighthEdition." (2006). Brumbach, Michael E., and Jeffrey A. Clade. Industrial maintenance. Cengage Learning, 2013. TEACHERS AND EXAM BOARD ROBERTO REVETRIA Ricevimento: The reception is to be arranged with the lecturer by appointment by sending an email to: roberto.revetria@unige.it The lecturer is available in the office every week except August. ANASTASIIA ROZHOK LESSONS LESSONS START https://corsi.unige.it/en/corsi/10377/studenti-orario Class schedule The timetable for this course is available here: Portale EasyAcademy EXAMS EXAM DESCRIPTION The exam is composed of three main parts: 20 multiple-choice quiz for a total of 25 points over 30 assignments for a total of 7 points over 30 oral examination for a total of 32 points over 30 The final grade is the average of (quiz + assignments) and oral examination. The oral examination is based on a presentation on a course topic chosen by the student and 3 open questions by the teacher. The exercises (assignments) must be delivered to the address: assignments.revetria@dime.unige.it by the exam day. Late exercises are not accepted. The exercises done in groups must report on all in the name of the group members. Similar exercises that do not correctly name the group members will be waived. For every wrong question given at quiz time -0.5 points are subtracted. ASSESSMENT METHODS Assignment 1 (individual): Deliverable: Report to be submitted before the examination. Assignment 2 (in a group): Deliverable: Report and PowerPoint presentation to be submitted before the examination. FURTHER INFORMATION Exercises, software use and seminars are offered during the lectures period.
