Lean business & Lean manufacturing
Learning for the bottom line:
Lean Manufacturing and Lean Business techniques have revolutionized many organizations in the last 20 years. Companies of varying backgrounds can be found implementing Lean as a vehicle to improve product quality, delivery performance and to reduce cost. In parallel many organizations also find themselves reaping the benefits of increased employee satisfaction through the true empowerment Lean provides.
Participants of this five-day workshop will be exposed to production system fundamentals and the most powerful lean tools. During this course, participants will learn how to eliminate waste in their processes. We demonstrate the superiority of pull systems and show different implementation options. Most concepts and tools will be applied during hands-on exercises. As part of the workshop participants will lean a traditional manufacturing process by applying the methods and tools they have learned.
Upon completion of the workshop participants will:
- Understand the philosophy and techniques of Lean.
- Be able to apply the Lean tools in their work environment.
- Immediately generate savings through the application of these techniques.
- Have experienced the application of the tools during the training week.
- Understand the organizational infrastructure requirements for Lean.
During the workshop these topics will be covered:
- Philosophy, methodology and tools of Lean business
- Process analysis
- Process mapping - This tool develops a system-based understanding of the existing process including settings, inputs, outputs, process steps and sequence of events
- Spaghetti charts - Evaluation of the physical flow and travel distance of product moving through the facility. This establishes a baseline for eliminating transport waste from the process
- Video process analysis - Using a video camera to capture process and waste information and analyze it in a structured manner. The tool helps participants to see and eliminate waste that is often not intuitively considered waste
- Lean Basics I & II
- Waste identification - Discussion of the 7 types of waste (overproduction, rework & rejects, inventory, motion, processing, waiting and transport) and the associated symptoms of each
- 5C - Discussion of the 5Cs (Clear out, configure, clean and check, conform, customize and practice). Explanation of how the 5Cs are key components in establishing workplace discipline
- Cell layout - Demonstration of several different types of cell configurations that are used today. The positives and negatives associated with each are demonstrated. Both inter-cell and intra-cell layout to maximize flow are discussed
- Visual workplace - Importance of a visual workplace and information requirements. Discussion of how to organize a work area visually with metrics, material information, issues, team information, etc
- Capacity analysis - Assessing the capacity of the process and identifying the constraints or bottlenecks. Includes learning how to use "capacity analysis worksheets"
- Standard work - Organizing the operator tasks so that the process minimizes motion and maximizes productivity within takt time. Includes learning how to use "standard operations worksheets"
- Line balancing - Understanding how to divide the work among the team so that it is balanced and meets the takt time
- Mixed model - Discussion on how to efficiently run a line with multiple configurations using a lean production system
- Takt time - The takt time establishes the beat of the factory and the lines. In this section participants learn its significance and how to calculate it. The takt time is used to establish resources and standard work
- Cross training - Discussion of the importance of cross training in assuring worker safety, minimizing worker fatigue and maximizing worker productivity both within and between subassembly cells and/or production line positions
- Product Delivery Systems I, II & III
- Push vs. Pull - Factual discussion and demonstration on how push and pull systems differ technically and how a pull system improves process performance. (Hands on exercises & simulation included)
- Line design (CONWIP to Kanban) - The options for a pull system lie on a spectrum and the proper selection depends on issues like shared resources, batch or flow processes and product mix. This module explores implementing a pull line in practice. (Hands on exercise included)