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Lean Manufacturing

 

LM1 - Concepts of Lean Manufacturing

Course Length: One full day; recommended for all employees

This course is a general education about Lean manufacturing derived from the Toyota Production System.  The philosophy, principles and techniques are described for participants and related to their particular company or industry.  Objectives and benefits of Lean are discussed, reinforced with real examples of the achievements of US firms that have adapted Lean to their businesses.  Attendees participate in hands-on exercises that demonstrate particular techniques.  Questions and interactive discussions are encouraged throughout the session.

LM2 - Value Stream Mapping

Course Length: One full day and one half day; recommended for anyone who will participate in continuous improvement teams

Wherever a product is made for a customer, there is a value stream, but seeing that stream can be difficult.  This Value Stream Mapping course provides a formal structure for teams to capture the information and process flows in any given value stream on a single document, both value-added and non value-added steps.  After receiving basic education in the process, participants put together a sample map with data provided in the training material.  They then create a current state map of one of their own processes.

On the second day (4 hours), participants create a future state map, comprised of an improved process they believe can be accomplished within the next three to four months.  A gap analysis between current state and future state is then completed, and the result is a plan for improving the process.

LM3 - Lean Workshops (Kaizen Blitz)

Course Length: Variable - 2 to 5 days depending on mandated goals; recommended for anyone participating in cross-functional teams

To maximize the benefits of classroom training, the workshops are conducted over 2-5 days using practices described in the Lean overview and value stream mapping modules.  Following a brief review of the management mandates, the workshop facilitator provides in-depth training for use of the tools needed to implement improvements.  Participant teams gather data from the target area(s) for evaluation.  The team brainstorms ideas, selects approaches, accepts assignments, and goes into the workplace to begin implementation.  Accomplishments and to-do lists are reviewed daily and a follow-up list is created for all work that can’t be completed during the event.  On the final afternoon of the event, team members present their accomplishments to management.  These workshops assure implementation, rather than lists of  “good things to do.”

LM4 - 5S/Visual Controls

Course Length: One full day; recommended for all employees

A Visual Workplace is one where everything has a place and is in its place.  Visual Control implies a work area that is self-explaining, self-regulating and continuously improving because it is visibly obvious where improvements need to be made.  This course introduces personnel to the concept of using visual signals and information to communicate simply.  It also introduces them to the 5S system (Sort, Store, Shine, Standardization, and Sustain), the technique most often recommended as the first Lean tool to introduce to the workforce.  The course includes a pilot evaluation of a work area, using a 5S checklist and formation of the first 5S team.

LM5 - Cellular Manufacturing/Material Flow

Course Length: One full day; recommended for anyone involved with production, material handling, planning, or manufacturing engineering

A cellular process is one in which a family of products or services is produced by a team of personnel who are multi-skilled and dedicated to production of that family of products or services.  In the ideal Lean environment, anyone should have a clear “line of sight” of the production process, from incoming raw material and components through to the packaging of the finished product, with little or no blockages to the flow.  Any blockage or non-value adding stoppage constitutes waste and must be eliminated.  The elements of cellular, the benefits of achieving flow, and what must be done to achieve flow in a production area are discussed.  The basic concepts may be applied to both manufacturing and service products.

LM6 - Mistake-Proof/Failsafe

Course Length: One full day; recommended for all employees

Mistake proofing (sometimes referred to as “poka-yoke”, but never fool proofing) is the use of practices or devices that make it difficult or impossible to do a task incorrectly or that prevent a defect from occurring.  Failsafe, a system created during the design phase of a process, makes it impossible for a process to continue if it will lead to injury or a defect  In addition, it will cause the process to continue functioning if stoppage would have catastrophic results.

This course introduces participants to mistake-proof and failsafe thinking.  This includes analysis questions, basic root cause analysis, discussing potential sources of error, a method to develop a MP/FS system, and some basic post-analysis questions to establish continuous improvement.

LM7 - Pull/Kanban

Course Length: One full day; recommended for anyone involved with the flow of material for production

Since this is one of the most misunderstood Lean tools, participants spend time learning the differences between a standard “push” production system versus a Lean “pull” production system.  This includes discussions of basic requirements for implementing a pull system, specific tools and formulas used to establish the system, and a basic project plan to implement a pull system.  The key to understanding the information is in a hands-on simulation, which can be a simple one-hour demonstration or a much more complex simulation that includes cost roll-ups, quality problems, and more in-depth discussion of issues.

LM8 - Setup Reduction

Course Length: One full day; recommended for setup personnel, operators, engineers, and management

The purpose of this course is to introduce participants to the concepts of setup reduction.  This highlights the effect of setup time on the operation as a whole and helps employees understand the advantages of reducing setup time.  They are also instructed how and where to start.  The course includes a hands-on demonstration, and the longer version provides the opportunity to apply information learned in the classroom to work on the shop floor.

LM9 - Setup Reduction Workshops

Course Length: Variable - 2-5 days, depending on mandated goals; recommended for setup personnel, operators, engineers, and management

Similar to the shorter version, this course introduces participants to the concepts of setup reduction to help them understand the effects of setup time on the operation as a whole.  The advantages of reducing setup time are detailed, along with how and where to start.  However, this workshop is intended to produce results that actually reduce setup time by the end of the event.  While it is possible to achieve positive results without it, we highly recommend that the setup be videotaped ahead of time to use as reference during the workshop.

 LM10 - Standard Work/Best Practices

Course Length: One full day; recommended for anyone responsible for work to be standardized

Standard work is the process to be used EVERYTIME by EVERYONE to accomplish the job.  This definition is not limited to the shop floor.  Standard work is the cornerstone of continuous improvement, the process of finding and eliminating waste.  This course introduces participants to tools that complete the job in the best, easiest, safest way, with predictable, high quality results for the customer.  The improvements are best developed by those currently doing the job, using the four key forms for standard work: Time Observation Form, Standard Work Combination Sheet, Standard Work Sheet, and Operator Loading Chart.

LM11 - Total Productive Maintenance Overview

Course Length: One full day; recommended for anyone responsible for equipment maintenance

This course lays the groundwork for implementing autonomous maintenance using a team-based approach.  Course content includes an introduction to the basic concepts and principles, including the six biggest losses that lower equipment efficiency, methods for breakdown elimination, and steps for implementing a TPM program. 

LM12 - Plant Layout for Lean Production

Course Length: One full day; recommended for Lean team members

This course focuses on tools and techniques for optimizing plant layout in existing or new facilities.  Participants learn how to simplify processes, incorporate flexibility, use space economically, minimize handling and improve safety.  They use tools such as block diagramming, activity-relationship charting, and flow diagram analysis.  Topics include cellular manufacturing, one-piece flow, and 5S/Visual Controls.

LM13 - Production and Inventory Control

Course Length: Variable; recommended for Lean team members

This course is designed to explore the benefits of applying Lean concepts to the materials management function.  This technique encompasses the complete cycle of material flow from the time of purchase through internal control of production materials.  It follows the planning and control of work in process through the warehousing, shipping, and distribution of finished goods.  This course will concentrate on methods to eliminate waste in production, material handling, warehousing, and shipping. 

Participants will learn Lean techniques for reducing scrap, optimizing inventory control, reducing raw material SKU’s, and implementing packaging recycling and reuse through vendor management programs.

NM1 - Lean in Service Organizations

Course Length: One full day; recommended for Lean team members

The basic principles of Lean manufacturing have also been applied successfully in non-manufacturing businesses.  This course is a general education on the basic reasons and benefits of Lean and how to develop Lean teamwork in the service sector.  Other topics covered are information flow maps, standard work, 5S in the office, quality defect detection, and paper flow.

 

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