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LeanManufacturingTraining|CourseOutline

LEANMANUFACTURING
ShowCourseObjectives

COURSEOUTLINE
UNIT1LEANCONCEPTS
LESSON1
WhyLean?

Becustomerfocused:Beontime,
responsive,flexible,andfast.
Simplifyandstandardizeworkflows:
Mimiccontinuousflow,minimizeWIP,
usevisiblemeasures.
Managecapacity:Increaseprocess
uptime,reducesetuptimes,find"lost"
capacity.
Eliminatewaste:Identifynonvalue
addingactivities,thenmodify,combine,
oreliminatethosetasks.
JiT:Nottooearlyandneverlatenot
justincaseinventorybutjustintime
productionanddeliveryproductsmust
alwaysbemaderightthefirsttime
equipmentmustalwaysworkwhen
needed.

LESSON2
LeanTerminology

Terms
Tools
Techniques

LESSON3
EliminateWaste

Matchlotsizestocustomerdemands:
UsekanbansendWIP.
Usepullschedulinginsteadofpush
scheduling.
Scheduletotheratedeterminingstep
(thebottleneck),thendebottleneck
processlines.
Facilitatefastfeedback:Arrange
sequentialoperationsnexttoeachother
toensurefastfeedbackfrominternal
customeroperationstointernalsupplier
operationsifsomethinginprocessisnot
right.

LESSON4
ComponentsofLean

Overviewofthe8ComponentsofLean:
ValueStreamMapping,Workplace
Organization,Predictability&

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LeanManufacturingTraining|CourseOutline

Consistency,SetupReduction,TPM,
VisualFactory,SupportProcesses,and
ContinuousImprovement.
LESSON5
ValueStreamAnalysis

Maptheprocessfromincomingorderto
outgoingproduct:Defineprocessgoals,
createthecurrentstatemap,and
establishprocessmetrics.
Usethecurrentstatemaptoidentify
potentialimprovements,conceivethe
futurestate.

LESSON6
TheLeanMindset

Eliminatingwasteisnotlimitedto
manufacturingthesametechniques
applytotheoffice,sales,finance,
maintenance,andevenR&Dprocesses
andprocedures.
Lean&SixSigmaarecomplementary.

UNITTEST
Challenge

Anassessmentofthelearnersprogressinthisunit.

UNIT2LEANPRACTICES
LESSON1
Streamliningthe
ValueStream

Identifyprocessgoals.
Collectandanalyzeprocessdata.
Createamacrofacilityworkflowto
determinehowtominimizehighvolume
traveldistances.
Conductamicroprocessworkflowto
applycellularconcepts,identifyand
removebottlenecks,andmovetopull
manufacturingwithkanbans.

LESSON2
Workplace
Organization

Applythe5Ss:Sort(clearingthework
area),SetinOrder(designating
locations),Shine(cleanlinessand
workplaceappearance),Standardize
(everyonedoingthingsthesameway),
andSustain(ingrainingitinthe
culture).

LESSON3
Predictability&
Consistency

UseDFA/DFMtodesignqualityin.
ConductGR&Rstoensurereliable
measurementsystemsareinplace.
EmploySPCtohelpensureprocesses
arepredictableandstable.
Reducevariationandimproveprocess
capabilitywithDOE.

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LeanManufacturingTraining|CourseOutline

Eliminatetherootcauseofdefectsusing
problemsolvingandmistakeproofing.
MovetoSixSigmaquality.
LESSON4
SetUpReduction

ApplySMEDconcepts.

LESSON5
TPM

TPMversusPM

LESSON6
VisualWorkplace

VisualWorkplace

Separateexternaltasks(externaltothe
process)frominternaltasks.

Developoperatorinvolvementinthe
equipmentandbeginpredictive
maintenancepractices.

Usestatusdisplayofperformancefor
dashboardorbalancedmeasuresand
COQresults.
Visualcontrols,suchassensoryalerts,
indicateifsomethingisoutofplace.
Markingonthefloor,kanbans,andons,
andpanelalarmsallhelpbuildavisual
controlinfrastructure.

LESSON7
SupportProcesses

Leantechniquesrequirechangesin
Purchasing,Scheduling,
Warehousing/Shipping,andAccounting
practices.

LESSON8
Continuous
Improvement

FightNIH(notinventedhere)attitudes
andleveragesuccesses.
Usekaizeneventsforrapid,targeted
improvementstoachievethefuture
state.
UseastandardizedProblemSolving
Model(e.g.DMAICor8D).
Beginanemployeeideasystem.

UNITTEST
Challenge

Anassessmentofthelearnersprogressinthisunit.

UNIT3IMPLEMENTINGLEAN
LESSON1
LeanStartswith
People

LeanStartswithPeople
Communicatethewhy,what,how,and
who.
Provideeducationintheconcepts.

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LeanManufacturingTraining|CourseOutline

Trainemployeesintoolsandtechniques
asneededtoachieveaflexible
workforce.
LESSON2
DataDrivesLean

Focuseffortsonprojectsthatleadto
tangiblesavings.
Calculationtechniquestogeneratedata
include:Timestudies,equipment
loading,TAKTtime,staffing
requirements,processyields,andCOQ.
SampleWorksheetscoveredinclude:
LeanProjectSummaryCellTarget
WorksheetDataCollectionFormfor
BasicEquipmentandUtilityParameters
ValueAddingAnalysisWorksheet
ProcessChangeOver/SetupWorksheet
SetUpReductionWorksheetandLot
SizeWorksheet.

LESSON3
LayoutOptions

Improvedlayoutsareaboutmoving
cubicfeet(notnumbersofitems),
eliminatingcrossoverpoints,arranging
theprocessinthenaturalfloworder
linkingprocessestominimizetimeand
distancemovingequipmenttogetherto
simulateacontinuousprocessflowand
puttinginternalcustomersandsuppliers
nexttoeachother.
Becarefultoidentifyanchorsor
monumentsdonotmovethem.
Typicallayoutoptionsareexplored.

LESSON4
LeanInventory
Practices

Minimizetripstoandfromthe
warehousebydesigningthewarehouse
toworkforyou.
UseABCinventorycategoriesto
prioritizeinventoryneedsandstorage
locations.

LESSON5
RoadmapforLean

Startwiththepeopleissues.
Focusonworkplaceorganization(the
5S's),then,usevaluestreamanalysis
andprocessworkflowanalysisto
establisheffectivelayouts.
Wheretofocusnextdependsonspecific
needs.
UsetargetedKaizeneventstospeed
changes.
Donotoverlooktheneedtomodify
supportprocesses(especiallyscheduling

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LeanManufacturingTraining|CourseOutline

andpurchasing).
LESSON6
LeanPitfalls

Notdocumentingthefinancial
impact/savings.
Lackofcommitmentfromleadership.
Usingtraditionalpurchasingpractices.
Notchangingschedulingtechniques.
Failuretoaddressworkforceissues.
Notmistakeproofingtherootcause.
ThinkingLeanisjustformanufacturing.
Notusingbeneficialtechnology.
Notleveragingsuccesses.
Gettingtoolean.
Failuretoholdthegains.

UNITTEST
Challenge

Anassessmentofthelearnersprogressinthisunit.

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