COURSE OBJECTIVES

  • Understand how Lean Management leads to productivity improvement and customer satisfaction.
  • Apply Lean Management both to manufacturing and business processes.
  • Identify different kinds of waste in the company.
  • Define the Value Stream Map and identify non-value-add steps 
  • Implement "PULL" management
  • Apply KANBAN to achieve PULL
  • Practice with Lean tools (VSM, 5S, TPM, Visual control, etc)
  • Develop a Lean Project 

INTRODUCTION

  • Just-in-case Vs Just-In-Time logistics
  • Line Vs workshop production
  • Production by lots Vs continuous flow

VALUE ADD MANAGEMENT

WASTE IDENTIFICATION AND REDUCTION

  •  8 Wastes: description
  •  Waste identification
  •  Go to Gemba

WORKPLACE ORGANIZATION

JUST IN TIME PRODUCTION

  •  Inventory level and manufacturing lot size
  •  Equipment setup time reduction: SMED
  •  Total Productive Maintenance: TPM
  •  Load balance: Heijunka
  •  Versatile operators: multi-skill
  •  Takt, machine cycle, operator cycle
  •  Line layout: production flexibility
  •  Materials flow in the plant: Spaghetti diagram

MATERIALS MANAGEMENT

QUALITY AND PROCESS IMPROVEMENT

  •  Jidoka: Do not pass defects
  •  Poka-Yoke: Fail-Proof processes
  •  Quality metrics: DPU, DPMO, FPY, etc.
  •  Failure Mode and Effects Analysis
  •  Six Sigma process improvement: DMAIC
  •  Customer complaints management: 8 discipline 
  •  Improvement teams: Kaizen Blitz events