LEAN MANUFACTURING (Process Improvement – 2 Modules)

Who should attend?

Company executives, production department managers, quality, maintenance, logistics, planning; Process engineers and product engineers, process improvement managers, continuous improvement specialists and operational performance specialists & anyone interested in understanding the lean manufacturing concept and lean techniques.

 

Why should you choose this course?

 

MODULE 1: INTRODUCTION TO LEAN MANUFACTURING - basic level

The Lean Manufacturing MODULE 1 -basic course provides an overview of what it means to operate with excellence in production and the basic concepts of lean strategy. It is built to help any industry specialist at any decision-making level understand key concepts and answer questions clearly such as:

"What does lean manufacturing mean?"
"What benefits do we have if we implement lean manufacturing?"
"What lean techniques exist and what is their logical order in lean implementation?"

In two and a half days, you will have a global understanding and details of techniques to achieve operational stability and engage people in a culture change that will bring substantial benefits to companies with minimum investment.

Course Materials:

- Production Simulator (AVIATION FACTORY)
- Course support
- Practical exercises
- Case studies
- Practical Work - Optional
- Certificate of Participation
- Professional Certificate in case of Practical Work

MODULE 2: LEAN MANUFACTURING - advanced level

The Advanced Lean MODULE 2 Manufacturing Course helps you identify and understand the tools needed to implement the lean strategy after reaching a level of operational stability.The emphasis in this training session is on understanding the concept of streamlining production activities, understanding methods and improving flow performance and ways of sustaining and continuously improving it.We will address answers to questions like:
"How do I implement a lean flow?"
"How do we support the stability and performance of a lean flow of value?"
"How can we measure the performance of a lean production stream?"
Keywords: flow, lead time, flexibility, standardized flow support activities

Course Materials:

- Production Simulator (AVIATION FACTORY)
- Course support
- Practical exercises
- Case studies
- Practical Work - Optional
- Certificate of Participation
- Professional Certificate in case of Practical Work

What is the structure of this course?

 

MODULE 1:  INTRODUCTION TO LEAN MANUFACTURING - basic level

Chapter 1: Lean Introduction

- History, definition, the 5 lean principles
- Lean a unitary system and a company strategy
- Toyota Production System (TPS)
- Value and waste (7 Muda)
- Operational stability - role in lean implementation, methods of controlling production -factors and reducing variability.
- Lean-concept, lead time, inhibitory factors and necessary conditions
- Airplane Factory - leanage simulation exercise

Chapter 2: 5S Method and Visual Management

Definition and objective of the 5s method and visual management
- Sorting
- Ordering
- Stabilization
- Standardization
- Support
- Benefits of 5S implementation: 5S simulation game

Chapter 3: Standardization in processes and management

Working standards
Standardized management activities
Standard streaming supervision route
Training Within industry - standard methods of managing training, working relationships and kaizen

Chapter 4: PDCA and Lean Problem Solving

Toyota method in 8 troubleshooting steps
Correctly defining a problem
Finding the Root Cause: Contributing Factors, Validation, Root Cause, 5 Whys Method, Fishbone Analysis
Countermeasure plan for problems
Verifying results and standardizing the solution

 

MODULE 2: LEAN MANUFACTURING - advanced level

Chapter 1: Lean manufacturing - short overview

-History, definition, the 5 lean principles
-Lean a unitary system and a company strategy; Toyota Production System (TPS)
-Lean-concept, lead time, inhibitory factors and necessary conditions
-Airplane Factory - leanage simulation exercise

Chapter 2: Total Productive Maintenance (TPM)

-Types of losses associated with production equipment
-OEE - Overall Equipment Effectiveness - a measure of performance of equipment
-SMED - Flexible production with fast changing methods of manufacturing

Chapter 3: Flow Redesign: Value Stream Mapping - Chain Mapping

-Flow-concept, traditional and lean production methods;
-Flow - the transition from production to pulled production and the flow of a single piece
-Product Families, X Matrix
-Case study: Value stream mapping
-Value stream mapping - importance, approach, steps in analyzing and improving the flow of value
-Current state - mapping and analysis of the current situation
-Future state - the map of an improved value stream;
-Designing the flow of value following the 8 flow design steps
-Implementing Future State-Action Plan, Flow Rules, Chain Value Managers

Chapter 4: Stream Support: Standardized work in a lean flow

-Standardized work of operators
-Standardized work of supervisors
-Standardized work of leaders
-Flow Performance Control: Fast Anomalies Detection, Andon Signals, Quick Response, Problem Solving

Calendar

Course date: 

Commercial conditions

Additional information on tel: 0726268256, 0727336314

For a group of 10-14 participants we can run an in-house course that can be delivered at your headquarter or in any location of your choice, on a mutually agreed date.

administrator-512

Trainer

Raluca Florea 

Testimonials

 

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