Wednesday 3 July 2013

Lean Manufacturing


Lean is a philosophy and set of management techniques focused on continuous “eliminating waste” so that every process, task or work action is made “value adding” (the real output customer pays for!!) as viewed from customer perspective. Lean “waste elimination” targets the “Eight Wastes”.

Through a mixture of presentations and discussions including group and individual exercises, this 2 day intensive training course will provide a systematic approach for Lean Management implementation practices applicable for both the manufacturing and maintenance environment. The student will be provided with a toolbox of techniques for problem solving, continuous improvement,plus practical advice ranging from operating a Lean facility on a day-to-day basis to understanding how to sustain the Lean program.


The program shall be conducted in an immensely practical manner through examples, illustrations, case studies, games, group work, data analysis and Q&A sessions with sharp focus on business results.


  1. Develop a Lean Program for Their Facility
  2. Measure Performance in Order to Achieve Desired Outcome
  3. Create Value Stream Mapping
  4. Enhance the Responsiveness and Effectiveness of Material Flows
  5. Forecast Demands Accurately to Improve Scheduling
  6. Manage Your Workforce Effectively for Continuous Improvement
  7. Implement Rapid Process Improvements
  8. Identify Wastes and How to Eliminate them
  9. Understand What in Needed to Sustain the Gains

Course Content

1. Lean Culture Executive Overview

Familiarize Participants with Lean concepts so they are able to:
  • Identify the basic principles and objectives of Lean
  • Define how continuous improvement is an ongoing activity and must be constantly reinforced
  • Define how change must be sponsored by management and move down
  • through the organization
  • Recognize how Lean tools and techniques help eliminate waste from processes

2. Value Stream Mapping

An overview of learning to see the flow of customer value from the product or service perspective and
be able to:
  • Identify and collect accurate data to design Current State Maps
  • Apply Lean icons to develop Value Stream Maps
  • Create a current state Value Stream Map
  • Identify areas of improvement to perform Kaizen events
  • Calculate takt time through a classroom exercise
  • Create a future state Value Stream Map

3. 5S-Workplace Organization

Enhance the organization of your workplace through the application of proven tools and be able to:
  • Recognize differences in appearance and functionality before and after a 5S implementation
  • Explain the potential benefits by implementing the concepts of Sort, Set in Order and Shine
  • Applications of basic Standard Work procedures that will help maintain and control an organized workplace using visual controls
  • Explain methods to Sustain workplace organization
  • Describe how 5S can help to improve workplace environmental health and safety

4. Poka Yoke
  • Understand and implement the Poka-Yoke methodology
  • Understand and practically employ the basic techniques associated with Zero Quality Control (ZQC) and Poka-Yoke
  • Identify where ZQC and Poka-Yoke can be used for best effect
  • Coordinate and motive the Poka-Yoke team to provide real, tangible solutions to what appear to be intractable quality problems
  • Train others in the ZQC and Poka-Yoke methodology

5. Standardize Work
  • Benefits of Standardized Work
  • Use standardized work basic concepts and examples from various industries
  • Observe work before you standardize it
  • Use the elements of standardized work (takt time, work sequence, standard in-process inventory)
  • Identify the documents for establishing standardized work (production capacity sheet, combination table, work chart).
  • Define the requirements for standardized work (work,equipment and line,quality)
  • Standardize: poka-yoke, visual systems, checking and auditing.
  • Choose the standardization techniques suitable for your environment so that you can effectively ensure your process is consistent and your results are predictable

6. Kanban
  • What is Kanban? - Definitions
  • Understanding the origins of Kanban
  • Comparison of Push vs. Pull Systems
  • Kanban Card Types (Withdrawal, Conveyance & Production)
  • Types of Kanban systems (One card and Dual Card)
  • Kanban System Characteristics
  • Strengths and Weaknesses of Kanban
  • Planning for change
  • How to implement Kanban?
  • How Kanban can interface with MRP/ERP systems?

7. Cellular Work Flow
  • Definition and benefits for U shaped cell design
  • Use of multi-skilled, multi-machine operators and small flexible machines
  • Use of Jidoka (Automation) to eliminate machine watching

8. Elements of a cell design
  • Process based layout
  • Standardized Work, 5S and Visual Management to support cellular
  • manufacturing
  • Autonomous cell maintenance activities
  • Cell activity boards and measures

9. Quick Changeover-Setup reduction (SMED)
  • Define and measure setup.
  • Define the four stages of SMED.
  • Identify Internal and External setup.
  • Apply techniques to convert internal setup to external setup
  • Identify inexpensive techniques to reduce internal setup time
  • Describe how SMED relates to Lean Manufacturing, especially small lot production

10.Total Productive Maintenance

Enhance plant and equipment reliability to increase productivity and be able to:
  • Identify the basic components of total productive maintenance
  • Describe the bath tub curve and machinery life cycles
  • Identify the Six Big losses in machinery
  • Design and implement autonomous maintenance plans
  • Train other operators in TPM activities
  • Assess the TPM needs of specific equipment to help achieve zero defects
  • Recognize faults and how to address them
  • Create a sample productive maintenance program for their plant

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