2024 ASEE Annual Conference & Exposition

Lean Six Sigma (LSS) has become an important topic these days in continuous process improvement. LSS is a combination of Lean principles of waste reduction and Six sigma methods of variation reduction. Combined, Lean Six Sigma becomes an immensely powerful tool for process improvement in today’s highly competitive markets wherein quality, productivity and cost are all important for customer satisfaction. A value stream map (VSM) is one of the most important and the most complex tool in lean.
Traditional teaching of VSM in undergraduate Lean Six Sigma class is achieved by firstly mapping the “As Is” state of the process and then converting the “As Is” VSM into a “To be” VSM by applying lean tools of Kanban, pull system and continuous flow has demonstrated lower student learning outcomes. So, herein we have discussed a new instructional strategy of using simulation software ‘Rockwell Arena’ to enable effective student learning in class. A simulation of “As Is” state VSM of a manufacturing process is prepared in Arena and displayed in class after completing traditional teaching of Value stream mapping topic. Further, students in the class suggest and discuss modifications to “As Is” state VSM in Arena Simulation, eventually forming the “To be” VSM of the process. To encourage student participation in class, instructional techniques like think, pair, share are used wherein students are paired in groups to think about a problem and later share their findings with the class.
A student questionnaire comparing student learning before and after instruction using Arena simulation are compiled. It is evident from data that student learning is greatly enhanced with the use of Arena simulation for teaching Value Stream Mapping in undergraduate Lean Six Sigma class.

Keywords: Simulation software, Rockwell Arena, Value Stream Mapping, Lean Six Sigma.