In Lean Manufacturing, you'll learn...
- The benefits of a lean company culture
- How to implement work process standardization
- How to design and implement an Improvement Plan
- How to reduce errors and increase quality
- And much more!
What if you could dramatically improve efficiency, reduce waste, improve quality and increase profit? You can—no matter what industry you’re in—by implementing Lean Manufacturing practices in your organization. Lean Manufacturing isn’t just for the production floor. It works in the office, retail store, health care facility, educational facility—virtually any business. In this course, you’ll find out what a lean culture is and how it can benefit your company. You’ll examine each area of Lean Manufacturing, learn step-by-step techniques that are easy to implement and gain valuable tips for how to analyze your results.
WORKSHOP AGENDA
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Lean Manufacturing overview+
- Find out what Lean Manufacturing is all about
- Discover the advantages of Lean Manufacturing over traditional manufacturing techniques
- Uncover the 10 rules of Lean Manufacturing
- Learn the true benefits of Lean Manufacturing
- Understand the 3 eras of manufacturing
- Learn the difference between continuous flow and batch processing
- Find out how standardization fits in the Lean Manufacturing model
- Learn how other components of Lean Manufacturing such as 5S, continuous improvement and others fit into the total picture of Lean Manufacturing
Lean culture+
- Uncover the benefits of a lean company culture
- Learn about the new paradigms that must be implemented for a successful lean culture
- Find out about the 6 most important factors that go into building a lean culture
- Learn why the shop floor culture is vitally important
- Understand the emphasis Lean Manufacturing places on waste
- Discover the 7 types of waste
- Find out why overproduction is the “deadliest” of the 7 wastes
Work process standardization+
- Find out what standards are and see how your personal standards match up with those of your department and those of your company
- Learn the real benefits of standardized work and find out what’s in it for the worker
- Learn how a conventional work environment compares to a standardized work environment
- Learn about the tools used for standardization
- Uncover the 3 factors of time that affect waste
- Find out what the standardization cycle of progress is and how it relates to the efficient use of lean management
Creating a visual factory through 5S management+
- Find out what visual management is and why you should use it
- Learn how to create a visual management system
- Find out how to make use of the 5S visual displays and controls
- Learn what Andon visual controls are and their 8 major benefits
- Learn what the value stream mapping process is and its 3 stages
Total Productive Maintenance (TPM)+
- Discover what TPM is really all about
- Learn the 5 objectives and 5 goals of TPM
- Find out what zero accidents, zero breakdowns and zero defects add up to
- Discover what goes into a program of planned maintenance
- Uncover the major causes of equipment problems no matter what industry you’re in
- Learn how to implement TPM and overcome poor practices in your company
- Find out how to determine if TPM is being effective
- Learn about the tools of TPM and how to use each one
- Discover the real advantages of implementing a TPM program
Designing and implementing an Improvement Plan+
- Learn the anatomy of an Improvement Plan
- Discover the goals of an Improvement Plan
- Find out how to determine the outcomes of an Improvement Plan
- Practice focusing on an Improvement Plan
- Follow these 10 steps to implementing an Improvement Plan
- Find out how to implement an Improvement Plan in 4 days
- Become skilled at avoiding Improvement Plan pitfalls
- Discover how efficient you should be—the 80/20 rule
- Recognize productivity and standardized work outcomes
- Identify the results of using an Improvement Plan
- Learn Improvement Plan prerequisites
- Learn how to use Improvement Plan tools
Essentials of Kanban+
- Learn the history of Kanban
- Understand the shortcomings of the Ford system
- Discover how Just in Time (JIT) can work for you
- What is Kanban?
- Distinguish between “Push” Production System and “Pull” Production System
- Find out about the basic “Pull” System using Kanban
- Discover how to schedule using Kanban
- Become familiar with the benefits of the Kanban Pull System
- Identify the functions of Kanban
- Learn the Kanban rules and recognize the types of Kanban
- Study Withdrawal Kanban cards
- Find out about Production Kanbans
- View sample production-ordering Kanban cards
- Discover how to put Kanban to work
- Become familiar with and learn the rules of Circulating Kanbans
- Identify transport rules with Kanbans
Rapid changeover+
- Review mass manufacturing concepts
- Learn new Lean Manufacturing concepts
- Find out about quick changeover
- Identify the benefits of quick changeover
- Learn set-up operations, procedures and analysis
- Find out about the steps to achieving quick set-up and changeover
- Become familiar with separating internal and external set-up
- Discover how to convert internal set-up to external set-up
- Become skilled at streamlining set-up operations
- Recognize external set-up improvements
- Recognize internal set-up improvements
Keeping bad things from happening … eliminating the errors!+
- Find out what Error Proofing is and where it comes from
- Review the old manufacturing model
- Learn the new model—Error Proofing
- Identify the two categories of Error Proofing (Poka-Yoke) devices
- Become familiar with prevention and detection devices
- Be aware of where Poka-Yoke works and where it doesn’t
- Learn the definition of and common causes of defect
- Learn to identify defects (small group—brainstorming)
- Recognize common errors
- Be aware of red flags (manufacturing processes that cause errors)
- Learn 6 principles of mistake-proofing
- Discover simple steps to mistake-proofing
- Recognize examples of manual and automated Poka-Yoke tools
- Learn how to ensure quality
- Understand in-station process control
Analyzing the results+
- Learn the characteristics of measurables in Lean Manufacturing
- Identify internal measurables
- Identify external measurables
- Study examples of lean measurables
- Learn what First Pass Yield is about
- Discover the importance of Overall Equipment Effectiveness (OEE)
- Identify Total Cycle Times
- Find out about Total Costs
- Become familiar with calculating costs
