Lean Manufacturing: Waste Reduction and Productivity Improvements

• Gain an understanding of the Waste Reduction Techniques and a methodology to incorporate changing requirements.
• Demonstrate need for Leadership involvement.
• Understand the assessment, review and improvement process using "Lean" waste reduction techniques.
• Define leadership key roles and responsibilities during the transition from implementation mode to sustaining and improvement of all processes.
• Provide concepts understanding of the "Lean" approach to allow evaluating the technique as an effective tool for identifying and driving focused improvement teamwork.
• Understand how to identify the 7 main sources of waste and concepts to eliminate them.

Content

Why less is more?

• Be customer focused: Be on-time, responsive, flexible & fast.
• Simplify & standardize workflows.
• Manage capacity: increase process uptime, reduce setup times, find lost capacity.
• Eliminate waste: identify non-value adding activities, then modify, combine, or eliminate those tasks.
• JIT: Just in Time concept

Wastes & Variation

• Key to identify types of wastes and variances in workplace.
• Project plan: How to eliminate and reduce wastes & variances in your workplace?
• Value Analysis - identify Value-Added (VA), Least Value-Added (LVA) & Non-Value-Added (NVA) Activities

Value Stream Analysis

• Mapping the process from incoming order to outgoing product: Define process goals, create the current state map, and establish process metrics.
• Using the current state map to identify potential improvements, conceive the future state.
• Create a macro-facility workflow to determine how to minimize high volume travel distances.
• Conduct a micro-process workflow to apply cellular concepts, identify & remove bottlenecks, move to pull manufacturing.
• Production Levelling

Workplace Design & Motion Study

• Process Flow analysis
• Therbligs analysis
• Motion Chart / Man-Machine Analysis
• Ergonomics Design / workplace

Lean & JIT Concepts

• Improving Layouts - arranging process in a natural flow order, building in ergonomics in workstation, linking processes to minimize time & distance, moving equipment together to simulate a continuous process flow; putting internal customers & suppliers next to each other.
• Pull System & Kanban concepts - designing processes & scheduling based on pull system, rather than push system,
• Calculating Kanban numbers for effective pull control
• Comparison of different Kanban & when to use them.

Setup Reduction

• Applying SMED concepts
• Process analysis to identify internal & external tasks - setup lead time analysis.

Supplier Partnership

• Enhancing & developing supplier-customer relationships
• Improving quality & delivery in supplier process

Total Productive Maintenance

• Types of Maintenance - Reactive, Preventive, Predictive, Prevention
• Understand machine / equipment efficiency - OEE calculation.

Roadmap for Reduction

• Start with the people issues - management and staff.
• Focus on workplace organization, use value stream analysis & process workflow analysis to establish effective layouts.
• Use targeted Kaizen / TQM events to speed changes.
• Whole Supply Chain Management Concept - from scheduling, purchasing, process to inventory.

For Whom:

Operation/Production Managers, Technicians, Machine Operators, Supervisors, Directors, and others who are involved in the day-to-day activities in the manufacturing sector.

Training Methodology

The training methodology combines lectures, discussions, group exercises and illustrations. Participants will gain both theoretical and practical knowledge of the topics. The emphasis is on the practical application of the topics and as a result participant will go back to the workplace with both the ability and the confidence to apply the techniques learned to their duties.