Lean Business Solutions PLT (LLP0003236-LGN)

LEAN MANUFACTURING BREAKTHROUGH TECHNIQUES

WORKSHOP DESCRIPTION

This workshop must be attended if your manufacturing operations need to become more
responsive to your customer’s needs.  You will be introduced to the many concepts that fall under the umbrella of lean manufacturing, more so you will also get tangible ideas that you can take back to work and implement.

For example, you will learn how to reduce cycle time and how to use workflows to develop effective and efficient plant layouts.  In addition, you will discover how cellular operation concepts can increase your productivity, flexibility and quality and deliver results that will enhance your bottom line.   This concept is based on Toyota production systems.

INTRODUCTION

Lean manufacturing is a process that can help you to substantially reduce inventories.  Work-In-Process, required floor space, cycle times and lead times.  It can also dramatically improve quality connecting processes and people to allow errors to be caught faster.

Continuous improvement and eliminating waste are fundamental principles in Lean Manufacturing systems.  Lean Manufacturing is based on setting standards aimed at continuous improvements by all team members through constantly eliminating waste.  It is an opportunity to change a flabby waste-filled operation into a toned and muscular manufacturing company.

This program is an antidote to stagnation and to Leap beyond today’s best practice.  This workshop provides a new manufacturing Diet.

LEARNING OBJECTIVES

  1. Manufacturing value analysis.
  2. Single piece flow system manufacturing by simulation.
  3. Cycle Time reduction by simulation.
  4. Waste reduction by simulation.
  5. Inventory and space reduction by simulation.
  6. Learn the Lean culture.

TARGET AUDIENCE

  • Senior Manufacturing Executive / Managers
  • Operating Managers - Production, Scheduling And Control
  • Maintenance Managers, Engineers And Supervisors
  • Manufacturing Engineering Managers
  • Materials And  Quality Managers
  • Manufacturing Or Industrial Engineers                                  
  • Training Managers
  • Supervisors
  • Technicians
  • Line Leaders

METHODOLOGY

  • Lectures
  • Simulations
  • Gemba - Practical on the production floor                                       
  • Group discussions and presentations
    *All participants are requested to bring along a calculator.

DURATION

  • 2 days in-house - 9.00am to 5.00pm
  • Training Fee – SBL Claimable (inclusive of training fees, materials and certificate of attendance).

WORKSHOP OUTLINE

DAY ONE

  1. Mass Manufacturing to Lean Manufacturing Systems
    • Grouping of machines layout towards cell layout
    • 1st Simulation (Not Lean)
      • participants will take part in some assembly operations performed in a traditional way
      • end of simulation calculate the group's performance
        • lead time, quality, productivity and inventory
  2. The Lean Principles
    • Value
    • The Value Stream
    • Flow system
    • Pull and the Kanban system
    • Perfection
  3. Manufacturing Value Calculation
    • Choose one of your products; calculate percentage of value added activities to your lead-time.
    • This calculation is like a blood test to your process that reveals the whole world of improvements needed in your organization.  It is a way forward to Lean transformation.
  4. The 8 wastes.
    • Identification and elimination of Muda, Mura and Muri.
  5. Kaizen Activities.
  6. Gemba - Practical on the actual product line (For in house only).

DAY TWO

  1. 2nd Simulation – The cell manufacturing
    • Reduction of manpower
    • Elimination of departmentalization or grouping of machines
    • Introduction of cell concept
    • End of simulation calculate the group's performance
      • lead time, quality, productivity and inventory
    • Cell manufacturing – cell layout.
  2. Lean Tools
    • The flow system
    • The pull system
    • The Drumbeat calculation (Takt time).
    • Value Stream Mapping
    • Quick Changeover (SMED)
    • Poka Yoke
  3. 3rd Simulation – Introducing the Pull System
    • Practice Kanban
    • Reduction of lot size and Heijunka
    • End of simulation calculate the group's performance
      • lead time, quality, productivity and inventory.
  4. The Jidoka concept and quality improvement
    • Poka Yoke
  5. Elimination of non-value add activities and balance the line.
    • Takt time calculation.
    • Manpower calculations
    • Gemba Genbutsu
    • A world class case study will be introduced.
    • Visual control.
  6. 4th Simulation (Lean) - A Group Project
    • The group to design their own assembly line using formulae learnt.
    • The group to eliminate all non-value add activities in their process and set up a lean line.
    • Practice standard work.
    • Line balancing.
    • End of simulation calculate the group's performance
      • lead time, quality, productivity and inventory.
    • Participants to compare the results of 1st, 2nd, 3rd & 4th simulation
    • To make an evaluation of what is value add and non-value add in your organization.
  • Lean Implementation Strategy.
  • Summary and Conclusion.

 

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