Lean Manufacturing Training _ Course Outline 521hx
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4/28/2015
Lean Manufacturing Training | Course Outline
LEAN MANUFACTURING Show Course Objectives
COURSE OUTLINE UNIT 1 LEAN CONCEPTS LESSON 1 Why Lean?
Be customer focused: Be ontime, responsive, flexible, and fast. Simplify and standardize workflows: Mimic continuous flow, minimize WIP, use visible measures. Manage capacity: Increase process uptime, reduce setup times, find "lost" capacity. Eliminate waste: Identify nonvalue adding activities, then modify, combine, or eliminate those tasks. JiT: Not too early and never late; not justincase inventory but justintime production and delivery; products must always be made right the first time; equipment must always work when needed.
LESSON 2 Lean Terminology
Tools Techniques
LESSON 3 Eliminate Waste
Match lot sizes to customer demands: Use kanbans; end WIP. Use pull scheduling instead of push scheduling. Schedule to the ratedetermining step (the bottleneck), then debottleneck process lines. Facilitate fast : Arrange sequential operations next to each other to ensure fast from internal customer operations to internal supplier operations if something inprocess is not right.
LESSON 4 Components of Lean
Overview of the 8 Components of Lean: Value Stream Mapping, Workplace Organization, Predictability &
http://www.qualitytrainingportal.com/courses_avail/44a_outln.htm
1/5
4/28/2015
Lean Manufacturing Training | Course Outline
Consistency, Setup Reduction, TPM, Visual Factory, Processes, and Continuous Improvement. LESSON 5 Value Stream Analysis
Map the process from incoming order to outgoing product: Define process goals, create the current state map, and establish process metrics. Use the current state map to identify potential improvements, conceive the future state.
LESSON 6 The Lean Mindset
Eliminating waste is not limited to manufacturing; the same techniques apply to the office, sales, finance, maintenance, and even R&D processes and procedures. Lean & Six Sigma are complementary.
UNIT TEST Challenge
An assessment of the learner’s progress in this unit.
UNIT 2 LEAN PRACTICES LESSON 1 Streamlining the Value Stream
Identify process goals. Collect and analyze process data. Create a macrofacility workflow to determine how to minimize high volume travel distances. Conduct a microprocess workflow to apply cellular concepts, identify and remove bottlenecks, and move to pull manufacturing with kanbans.
LESSON 2 Workplace Organization
Apply the 5Ss: Sort (clearing the work area), Set in Order (designating locations), Shine (cleanliness and workplace appearance), Standardize (everyone doing things the same way), and Sustain (ingraining it in the culture).
LESSON 3 Predictability & Consistency
Use DFA/DFM to design quality in. Conduct GR&Rs to ensure reliable measurement systems are in place. Employ SPC to help ensure processes are predictable and stable. Reduce variation and improve process capability with DOE.
http://www.qualitytrainingportal.com/courses_avail/44a_outln.htm
2/5
4/28/2015
Lean Manufacturing Training | Course Outline
Eliminate the root cause of defects using problemsolving and mistakeproofing. Move to Six Sigma quality. LESSON 4 SetUp Reduction
Apply SMED concepts.
LESSON 5 TPM
TPM versus PM
LESSON 6 Visual Workplace
Visual Workplace
Separate external tasks (external to the process) from internal tasks.
Develop operator involvement in the equipment and begin predictive maintenance practices.
Use status display of performance for dashboard or balanced measures and COQ results. Visual controls, such as sensory alerts, indicate if something is out of place. Marking on the floor, kanbans, andons, and alarms all help build a visual control infrastructure.
LESSON 7 Processes
Lean techniques require changes in Purchasing, Scheduling, Warehousing/Shipping, and ing practices.
LESSON 8 Continuous Improvement
Fight NIH (notinventedhere) attitudes and leverage successes. Use kaizen events for rapid, targeted improvements to achieve the future state. Use a standardized ProblemSolving Model (e.g. DMAIC or 8D). Begin an employee idea system.
UNIT TEST Challenge
An assessment of the learner’s progress in this unit.
UNIT 3 IMPLEMENTING LEAN LESSON 1 Lean Starts with People
Lean Starts with People Communicate the why, what, how, and who. Provide education in the concepts.
http://www.qualitytrainingportal.com/courses_avail/44a_outln.htm
3/5
4/28/2015
Lean Manufacturing Training | Course Outline
Train employees in tools and techniques as needed to achieve a flexible workforce. LESSON 2 Data Drives Lean
Focus efforts on projects that lead to tangible savings. Calculation techniques to generate data include: Time studies, equipment loading, TAKT time, staffing requirements, process yields, and COQ. Sample Worksheets covered include: Lean Project Summary; Cell Target Worksheet; Data Collection Form for Basic Equipment and Utility Parameters; ValueAdding Analysis Worksheet; Process ChangeOver/Setup Worksheet; SetUp Reduction Worksheet; and Lot Size Worksheet.
LESSON 3 Layout Options
Improved layouts are about moving cubic feet (not numbers of items), eliminating crossover points, arranging the process in the natural flow order; linking processes to minimize time and distance; moving equipment together to simulate a continuous process flow; and putting internal customers and suppliers next to each other. Be careful to identify anchors or monuments; do not move them. Typical layout options are explored.
LESSON 4 Lean Inventory Practices
Minimize trips to and from the warehouse by deg the warehouse to work for you. Use ABC inventory categories to prioritize inventory needs and storage locations.
LESSON 5 Roap for Lean
Start with the people issues. Focus on workplace organization (the 5S's), then, use value stream analysis and process workflow analysis to establish effective layouts. Where to focus next depends on specific needs. Use targeted Kaizen events to speed changes. Do not overlook the need to modify processes (especially scheduling
http://www.qualitytrainingportal.com/courses_avail/44a_outln.htm
4/5
4/28/2015
Lean Manufacturing Training | Course Outline
and purchasing). LESSON 6 Lean Pitfalls
Not documenting the financial impact/savings. Lack of commitment from leadership. Using traditional purchasing practices. Not changing scheduling techniques. Failure to address workforce issues. Not mistakeproofing the root cause. Thinking Lean is just for manufacturing. Not using beneficial technology. Not leveraging successes. Getting too lean. Failure to hold the gains.
UNIT TEST Challenge
An assessment of the learner’s progress in this unit.
Go to QualityTrainingPortal.com home
http://www.qualitytrainingportal.com/courses_avail/44a_outln.htm
5/5
Lean Manufacturing Training | Course Outline
LEAN MANUFACTURING Show Course Objectives
COURSE OUTLINE UNIT 1 LEAN CONCEPTS LESSON 1 Why Lean?
Be customer focused: Be ontime, responsive, flexible, and fast. Simplify and standardize workflows: Mimic continuous flow, minimize WIP, use visible measures. Manage capacity: Increase process uptime, reduce setup times, find "lost" capacity. Eliminate waste: Identify nonvalue adding activities, then modify, combine, or eliminate those tasks. JiT: Not too early and never late; not justincase inventory but justintime production and delivery; products must always be made right the first time; equipment must always work when needed.
LESSON 2 Lean Terminology
Tools Techniques
LESSON 3 Eliminate Waste
Match lot sizes to customer demands: Use kanbans; end WIP. Use pull scheduling instead of push scheduling. Schedule to the ratedetermining step (the bottleneck), then debottleneck process lines. Facilitate fast : Arrange sequential operations next to each other to ensure fast from internal customer operations to internal supplier operations if something inprocess is not right.
LESSON 4 Components of Lean
Overview of the 8 Components of Lean: Value Stream Mapping, Workplace Organization, Predictability &
http://www.qualitytrainingportal.com/courses_avail/44a_outln.htm
1/5
4/28/2015
Lean Manufacturing Training | Course Outline
Consistency, Setup Reduction, TPM, Visual Factory, Processes, and Continuous Improvement. LESSON 5 Value Stream Analysis
Map the process from incoming order to outgoing product: Define process goals, create the current state map, and establish process metrics. Use the current state map to identify potential improvements, conceive the future state.
LESSON 6 The Lean Mindset
Eliminating waste is not limited to manufacturing; the same techniques apply to the office, sales, finance, maintenance, and even R&D processes and procedures. Lean & Six Sigma are complementary.
UNIT TEST Challenge
An assessment of the learner’s progress in this unit.
UNIT 2 LEAN PRACTICES LESSON 1 Streamlining the Value Stream
Identify process goals. Collect and analyze process data. Create a macrofacility workflow to determine how to minimize high volume travel distances. Conduct a microprocess workflow to apply cellular concepts, identify and remove bottlenecks, and move to pull manufacturing with kanbans.
LESSON 2 Workplace Organization
Apply the 5Ss: Sort (clearing the work area), Set in Order (designating locations), Shine (cleanliness and workplace appearance), Standardize (everyone doing things the same way), and Sustain (ingraining it in the culture).
LESSON 3 Predictability & Consistency
Use DFA/DFM to design quality in. Conduct GR&Rs to ensure reliable measurement systems are in place. Employ SPC to help ensure processes are predictable and stable. Reduce variation and improve process capability with DOE.
http://www.qualitytrainingportal.com/courses_avail/44a_outln.htm
2/5
4/28/2015
Lean Manufacturing Training | Course Outline
Eliminate the root cause of defects using problemsolving and mistakeproofing. Move to Six Sigma quality. LESSON 4 SetUp Reduction
Apply SMED concepts.
LESSON 5 TPM
TPM versus PM
LESSON 6 Visual Workplace
Visual Workplace
Separate external tasks (external to the process) from internal tasks.
Develop operator involvement in the equipment and begin predictive maintenance practices.
Use status display of performance for dashboard or balanced measures and COQ results. Visual controls, such as sensory alerts, indicate if something is out of place. Marking on the floor, kanbans, andons, and alarms all help build a visual control infrastructure.
LESSON 7 Processes
Lean techniques require changes in Purchasing, Scheduling, Warehousing/Shipping, and ing practices.
LESSON 8 Continuous Improvement
Fight NIH (notinventedhere) attitudes and leverage successes. Use kaizen events for rapid, targeted improvements to achieve the future state. Use a standardized ProblemSolving Model (e.g. DMAIC or 8D). Begin an employee idea system.
UNIT TEST Challenge
An assessment of the learner’s progress in this unit.
UNIT 3 IMPLEMENTING LEAN LESSON 1 Lean Starts with People
Lean Starts with People Communicate the why, what, how, and who. Provide education in the concepts.
http://www.qualitytrainingportal.com/courses_avail/44a_outln.htm
3/5
4/28/2015
Lean Manufacturing Training | Course Outline
Train employees in tools and techniques as needed to achieve a flexible workforce. LESSON 2 Data Drives Lean
Focus efforts on projects that lead to tangible savings. Calculation techniques to generate data include: Time studies, equipment loading, TAKT time, staffing requirements, process yields, and COQ. Sample Worksheets covered include: Lean Project Summary; Cell Target Worksheet; Data Collection Form for Basic Equipment and Utility Parameters; ValueAdding Analysis Worksheet; Process ChangeOver/Setup Worksheet; SetUp Reduction Worksheet; and Lot Size Worksheet.
LESSON 3 Layout Options
Improved layouts are about moving cubic feet (not numbers of items), eliminating crossover points, arranging the process in the natural flow order; linking processes to minimize time and distance; moving equipment together to simulate a continuous process flow; and putting internal customers and suppliers next to each other. Be careful to identify anchors or monuments; do not move them. Typical layout options are explored.
LESSON 4 Lean Inventory Practices
Minimize trips to and from the warehouse by deg the warehouse to work for you. Use ABC inventory categories to prioritize inventory needs and storage locations.
LESSON 5 Roap for Lean
Start with the people issues. Focus on workplace organization (the 5S's), then, use value stream analysis and process workflow analysis to establish effective layouts. Where to focus next depends on specific needs. Use targeted Kaizen events to speed changes. Do not overlook the need to modify processes (especially scheduling
http://www.qualitytrainingportal.com/courses_avail/44a_outln.htm
4/5
4/28/2015
Lean Manufacturing Training | Course Outline
and purchasing). LESSON 6 Lean Pitfalls
Not documenting the financial impact/savings. Lack of commitment from leadership. Using traditional purchasing practices. Not changing scheduling techniques. Failure to address workforce issues. Not mistakeproofing the root cause. Thinking Lean is just for manufacturing. Not using beneficial technology. Not leveraging successes. Getting too lean. Failure to hold the gains.
UNIT TEST Challenge
An assessment of the learner’s progress in this unit.
Go to QualityTrainingPortal.com home
http://www.qualitytrainingportal.com/courses_avail/44a_outln.htm
5/5
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