LEAN

Course: LEAN Manufacturing Tools

Duration: 4 Days Contact Time

Venue: In-House

Objectives and Benefits:

The objectives of this programme are designed to provide delegates with a detailed knowledge of the key tools involved in introducing LEAN Manufacturing.

The workshop will provide participants with the knowledge and skill to:

• Enable the introduction of LEAN improvement activities in their area of responsibility.
• Participate in the implementation of LEAN principles Company-Wide.

Benefits:

• Decreased cycle time
• Less inventory
• Increased productivity
• Increased capital equipment utilisation.

Participants: The Programme is aimed at company personnel in Materials, Quality, Engineering and Production. Each participant will be required to identify a LEAN Improvement Project.

Course Agenda:

Day 1

Unit 1 - Lean Thinking

• History of Lean Manufacturing
• Differences between Lean Manufacturing and Mass Production
• The 5 Lean Principles
• Understanding Value (in the eyes of the customer)
• Recognizing the 7 wastes

Unit 2 - Takt Time and Standard Work

• The benefits of a Standard Work System
• The elements of Standard Work
• Conducting Process Observation to determine element cycle times
• Configuring Standard Work for minimum use of labour, materials and equipment
• Documenting results on a Standard Work Chart

Day 2

Unit 3 - Lean Material Systems and Kanban

• The benefits of a Kanban system
• Selecting an appropriate Kanban system
• Setting up a Kanban systems (calculating the number of cards required)
• The benefits of a Timed Delivery route

Unit 4 - Improvement Cycles

• Understanding the Plan-Do-Check-Act (PDCA) improvement cycle
• Selecting appropriate improvement tools
• Distinguishing between Root causes, Direct causes and Contributory causes
• Identifying appropriate Corrective and Preventive actions
• Construct a problem definition and SMART objectives
• Differences between Incremental and Breakthrough Improvement

Unit 5 - Value Stream Mapping

• The benefits of Value Stream Mapping
• The four stages of Value Stream Mapping
• Selecting appropriate products/product families
• Creating the Current State Value Stream Map
• Assessing the Current State Value Stream Map
• Developing the Future State Value Stream Map
• Creating an action plan to achieve the desired improvements

Day 3

Unit 6 - Lean Foundations

• The benefits of Workplace Organisation
• Implementing 5S Workplace Organisation
• Implementing appropriate Visual Control Systems
• The benefits of Total Productive Maintenance (TPM)
• Understanding the elements of the Overall Equipment Effectiveness (OEE) metric
• Implementing a basic Total Productive Maintenance (TPM) system to improve Overall Equipment Effectiveness (OEE)

Unit 7 - Quick Changeovers (The SMED System)

• The benefits of a Single Minute Exchange of Die (SMED) System
• The four stages of SMED
• Implementing SMED to reduce Changeover time

Unit 8 - Kaizen Events

• The benefits of a Kaizen Events
• Appropriate situations for a Kaizen Event
• Selecting appropriate team-members
• Identifying Kaizen Event goals
• Participating in a Kaizen Event

Unit 9 - Quality, Mistake-proofing and Line Layout

• Understanding the interaction between quality and lean manufacturing
• The principles of Mistake-proofing
• Selecting appropriate mistake proofing devices
• Selecting or devising an appropriate line layout to minimise waste

Day 4

• Project presentations
• Skills demonstrations

Course Fee: Fees supplied on request -