Module 01 — The value chain
What an industry actually is
Where a factory sits between a raw material and a customer, and why breaking one link stops everything after it.
In the room
Trace one object in the room back through every hand that touched it.
Production · Planning · Sourcing · Logistics
Module 02 — Operations excellence
How a factory runs
Flow, takt and the constraint. Why a line moves at the speed of its slowest station, not its fastest.
In the room
Run a five-station paper line, measure it, find your own bottleneck and rebalance it.
Industrial engineer · Line supervisor · Planner
Module 03 — 5S and the eight wastes
Everything has a home
5S is not tidying up — it is making problems visible. Then the eight wastes, and how to see them once you know their names.
In the room
Build a shadow board for the classroom, then walk a real school process with a stopwatch and tag every waste.
Continuous improvement · Lean · Kaizen
Module 04 — Quality management
How we know it is good
What a defect is, why measurement itself has to be proved, and why finding a fault at the customer costs a hundred times more.
In the room
Three students measure one object and disagree. That is gauge R&R, felt rather than taught.
Quality engineer · Metrology · Supplier quality
Module 05 — Total productive maintenance
Why machines stop
Availability, the six big losses and OEE — and why the person who runs the machine is the right person to look after it.
In the room
Measure your own classroom’s availability for a week, Pareto the losses, then fix the biggest one.
Maintenance · Reliability · Planning
Module 06 — AI and digitalisation
How machines learn
What a model actually is, where it helps on a line, and why bad data beats a good model every time.
In the room
Train an image classifier on good and defective parts, then break it deliberately and work out why.
Data engineer · ML engineer · Vision
Module 07 — IoT and connected machines
Machines that talk
Sense, connect, store, decide, act. How ten thousand cheap sensors became the industrial internet of things.
In the room
Wire a sensor to count objects passing, log it with a timestamp, and plot a day of it.
Automation · Controls · Industry 4.0
Module 08 — Environment and responsibility
What it costs the planet
Energy, water, waste and carbon as measured process losses — and what a student can actually be responsible for.
In the room
Audit the school’s energy and waste, cost the fix in rupees, and hand the proposal to the principal.
EHS · Sustainability · Energy · Compliance