Waste Reduction and Productivity Improvement

The Waste Reduction and Productivity Improvement Course will cover the following topics and more:

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

Course Booking

Please use the "Book Now" or "Inquire" buttons on this page to reserve your space or request for more information