Principles of Lean Manufacturing 101 is a one-day customized class where students will learn the principles of lean manufacturing and how to apply them within their facility. This training includes a simulation that enables the student to apply the lean concepts such as standardized work, visual signals, batch size reduction, and pull systems to name a few. This training gives the student firsthand knowledge of how to improve quality, reduce cycle time, improve performance delivery and reduce work in process.
5S System is designed to improve workplace organization and standardization. Participants learn the concepts of the 5S System and then apply them to transform a cluttered, disorganized area into a clean, organized, and orderly workplace. The course offers an opportunity to experience firsthand how the 5S system reduces waste and improves productivity and quality in a simulated production facility. Participants will learn to describe the difference in workplace appearance and functionality before and after the 5S process has been applied. Participants perform an in-depth audit of workplace organization and standardization; organize a workplace by applying the concepts of sort, set-in order and shine; standardize procedures to maintain and control an organized workplace using visual controls; and understand how 5S can help to improve workplace environmental health and safety.
Setup Reduction is a one-day, hands-on training session that builds on the principles of the Single Minute Exchange of Dies (SMED) system, developed by Shigeo Shingo, to dramatically reduce or eliminate changeover time. This four-step changeover improvement process is used to help companies design no/low cost solutions to reduce changeover time. By the end of the day the participant will experience reduced costs and setup times and see machine capacity increase at the same time.
Total Productive Maintenance (TPM) is a process to maximize the productivity of the company’s equipment for its entire life. This one-day, hands-on training session teaches about Overall Equipment Effectiveness, the six major equipment-related losses, and the causes of 75% of equipment breakdowns. The training will allow the company to experience how to achieve dramatic improvements in uptime and increased equipment effectiveness.
Value Stream Mapping (VSM) is a powerful tool used to create a material and information flow map of a product or process. It allows companies to map the flow of products and information from order to cash as well as throughout the supply chain. This customized two-day workshop provides the use of a powerful VSM tool to create a current state map and find non-value added activities. This course also assists in developing an implementation plan for attacking those non-value added activities.
Cellular-Flow Manufacturing (CFM) is a one-day workshop designed to slash lead time and increase productivity by improving product flow. Students will learn to transform their traditional batch production area to a cellular layout and see the dramatic changes in the way the product flows, so that customer demand is met – on time, every time.
Pull Systems/Kanban is a one-day workshop designed to improve cash flow, throughput and competitive position. Pull Systems/Kanban control the flow of resources in a production process by replacing only what has been consumed. They are customer order-driven production schedules based on actual demand and consumption rather than forecasting. This can help you eliminate waste in handling, storing and getting the product to the customer on time.
Kaizen is a focused approach to process improvement. This continuous improvement methodology combines lean tools such as 5S’s of Workplace Organization and Standardization, Cells, Pull/Kanban, Setup Reduction and Line Balancing. Each tool incorporates team empowerment, brainstorming and problem solving to rapidly make improvements to a specific product or portions of your processes. The results are real time with implementation occurring within one week. Not only do you see immediate improvements to your process, you will also develop a list of other improvement opportunities that the staff can investigate and implement after the Kaizen.
Lean Office/Workplace Organization is designed to improve workplace organization and standardization. Lean Office is part of an integrated suite of MEP tools and services developed specifically for small organizations. This full-day workshop involves a mix of classroom-style learning with an interactive live simulation where class participants take on the roles of managers and workers within a company. Workshop participants will learn lean definitions and techniques; explore the application of lean techniques in a simulated office. Participants will ultimately transform the simulated office in three “stages” or “days” by implementing proven lean techniques at the end of each “stage” or “day.” At the end of the workshop, the participants will have redesigned a leaner office that improves customer and employee satisfaction and speeds the order-to-cash cycle.
Value Stream Mapping Office is a tool used to create a material and information flow map of a product or process. This powerful tool allows companies to map the flow of products and information from order to cash as well as throughout the supply chain. This customized two-day workshop provides the use of a powerful VSM tool to create a current state map and find non-value added activities targeted at the front office.
Lean Enterprise Assessment is a two half-day workshop designed to identify the company’s strengths and weaknesses and how to effectively address those opportunities. The results include a report with recommendations for improvement opportunities.
Executive Leadership Training is an 8-hour class to assist the company’s leadership/owners on how to transform to a Lean Culture. The highlights of the Leading Lean workshop used in this training are communicating the need for change; assessment and planning; implementation & Kaizan; performance measurement and monitoring; and sustaining the process. Follow-on coaching is available.
Class duration and size details:
|
Lean Manufacturing Training |
Total Training Hours |
Student Minimums/Maximums |
|
Lean 101
5S
Setup Reduction
Total Productive Maintenance
Value Stream Mapping
Cellular Flow Manufacturing
Pull Systems/Kanban
Kaizen Event
Lean Office/Workplace Organization
Value Stream Mapping Office
Lean Enterprise Assessment
Executive Leadership Training |
8 Hours
8 Hours
8 Hours
8 Hours
16 Hours
8 Hours
8 Hours
8 Hours
8 Hours
16 Hours
8 Hours
8 Hours |
20 Students Max per Session (14 minimum)
6- 10 Students Max per Session
6 – 10 Students Max per Session
6 – 10 Students Max per Session
12 Students Max per Session
8 – 12 Students Max per Session
8 – 12 Students Max per Session
8 – 12 Students Max per Session
8 – 12 Students Max per Session
6 – 8 Students Max per Session
3 – 5 Students Max per Session
6 – 10 Students Max per Session |
