Lean Manufacturing Principles
Course Description
Provide class participants with the skill sets needed to support a lean implementation. Class is offered in 12 hours (suggest three 4-hour sessions scheduled over a 3 to 4 week period, though it can be accomplished in two consecutive days.) Ideally, the training is done in a cross-functional team environment.
Audience
All team members (supervision and engineering through to operators as well as non manufacturing personnel. Cross-functional representation is preferred.
Course Outline:
Module 1 - Lean Manufacturing Overview
- Lean defined (What it is and is not)
- A brief history of Lean (From Henry Ford at the turn of the century to Toyota today)
- Waste elimination process
Module 2 - Process Mapping
- Flow charting the process
- Utilizing the SIPOC model (Supplier-Input-Process-Output-Customer)
- Determining Value vs. Non-Value added
- Process mapping (departmental flow)
- Value Stream Mapping
Module 3 - The Seven Wastes
- De-constructing waste
- Overproduction waste
- Waiting waste
- Transportation waste
- Inventory waste
- Motion waste
- Defect waste
Module 4 - Implementing 5S
- The 5 S Philosophy
- Seri –Sort and Discard
- Seiton –Organize and Arrange
- Seiso -Clean, Tidy and Inspect
- Seiketsu –Maintain the system
- Shitsuke –Establishing the Belief and Culture
Module 5 - Kaizen, Poka-yoke and Visual Management
- Kaizen philosophy of Continuous Improvement
- Poka yoke process of Mistake Proofing
- Visual Management (Line of sight, performance metrics visible, marking of area)
- Andon lights (Green/Yellow/Red)
- Use of silhouettes
- Dashboards and metric performance
Module 6 - Line Balancing and Cycle Time Reduction
- Calculating Total Cycle Time
- Determining Demand at Capacity
- Identifying bottlenecks and Idle Time
- Calculating Takt Time
- Line Balancing Methods
Issuance of Final Exam