This project is designed and implemented a stimulated workstation assembly module using Lego components that teaches the core Industrial Engineering (IE) techniques and tools to students in an interactive way to increase learning efficiency. The primary objective is to demonstrate the application of Six Sigma concepts, Statistical Quality Control (SQC), Inventory Analysis, and manufacturing systems and methods by having the students go through the Lego train assembly process and learn about systemized production. A picture-based instruction manual was developed to ensure ease of assembly and to test different concepts, and the process was tested by third-party users to validate clarity and effectiveness.
We created two different strategies: the unoptimised and optimised modules to show concepts of process improvement, defect reduction, and IE concepts. In our first strategy, the defect rate was higher than that in the second module. For our unoptimised module, we had high defects because of an unclear instruction manual and unorganized Lego pieces. To solve this, we made different additional stations with different types of quantities of required pieces so students could understand how inventory affects the production lines along with better clarity in the instructions.