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J.H. Berk and Associates

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The Blog

Lean Manufacturing

 

Lean Manufacturing is a 10-class, 16-hour program of instruction addressing the fundamentals of this exciting operations management philosophy.  Lean Manufacturing encompasses a set of technologies that slash lead times, improve on-time delivery performance, reduce waste, and lower costs dramatically.  The program provides in-depth coverage of Lean Manufacturing management technologies that work - there's no fluff here!.  It contains numerous real-world examples based on production challenges in a variety of industries

 

Lean Manufacturing will provide attendees with the ability to:

  • Implement one-piece flow based on Takt times and design a manufacturing system with Takt times meeting customer requirements.

  • Rapidly implement cellular manufacturing approaches.

  • Minimize inventory while increasing throughput with setup reduction techniques, minimized travel and floor space layouts, and pull-based manufacturing.

  • Use Delay Ratio techniques to eliminate lost time.

  • Utilize Visual Manufacturing and the 5S approach for clean, organized, and efficient work areas.

  • Minimize inventory costs by focusing on defect prevention instead of detection.

  • Overcome resistance to change.

  • Use Production Dashboards to know performance against plan status, identify where variances exist, and rapidly get back on plan.

  • Use all of the above techniques to reliably make what is needed, when needed, in the amounts needed.

Prerequisites for this program include a background or interest in optimizing manufacturing efficiency. Industry-based case studies are used extensively in this program, and during the program attendees are encouraged to share their experiences and challenges with others.

 

Materials

  • Cost Reduction and Optimization for Manufacturing and Industrial Companies

Who Should Attend

 

Executives, managers, engineers, quality assurance specialists, supply chain management specialists, and others desiring improved operational performance.

Lean Manufacturing Course Outline

  • Module 1:  Introductory Lean Manufacturing Concepts.  Manufacturing management challenges. Manufacturing Requirements Planning and Just-In-Time manufacturing management concepts.  Lean Manufacturing overview. Pull production and cellular manufacturing.  Robust processes and quality improvement.  Eliminating lost time.  Setup time reduction.  Phased inventory.  Work-in-Process reduction.  The Toyota system.  Case studies.  Group discussion.

  • Module 2:  Finding and Eliminating Lost Time.  Lost time definitions.  Production time versus lost time.   Lost time causes.  Plant layout, inventory location, and process limitation factors.  Delay ratio analysis overview.  Preparing the delay ratio analysis.   Delay ratio analysis results interpretation.   Acting on delay ratio analysis findings.  The power of recovering lost time.  Conquering lost time.  Case studies and delay ratio analysis example. 

  • Module 3:  Takt Time, Capacity, and Load Considerations.  Takt time definition and implications. Takt time versus cycle time.  Capacity definitions.  Load definitions.  Capacity versus load considerations.  The relationship between takt time, capacity, and load, and how these factors affect efficiency and the ability to deliver products on schedule.  Determining takt time, capacity, and load.  Capacity versus load analysis.  Finding and using hidden capacity.  Case studies.

  • Module 4:  Lean Production Flow.   Defining the existing process.  Flow charting.  Identifying and eliminating unnecessary steps.  Optimizing the process flow.  Identifying and eliminating redundant work.  Defining optimized quality assurance points.  Identifying tooling and material requirements at each step.  Plant layout considerations.  Advantages and disadvantages of straight line versus cellular flows.  Balancing the operation.  Lost time considerations.  Sample layouts.  Case studies.  

  • Module 5:  Setup Time Reduction.  Setup time definition, philosophies, and reduction approaches.   Setup as a lost time driver.  Setup reduction advantages.  Setup reduction approaches.  Instilling operator, manufacturing engineer, numerically-controlled-machine programmer, engineer, and supervisor teamwork in reducing setup times.   Fixturing, tooling, procedural, and storage considerations.   Prekitting.  Minimizing walking, fastening, and adjustment.  Internal versus external setup considerations.  Case studies. 

  •  Module 6:  Process and Product Robustness.  Robustness definition.  Objectively identifying nonconformance history and potential nonconformance causes.  Quality measurement systems.  Unearthing failure causes in simple and complex systems.  Using failure mode assessment and assignment matrices.  Corrective action options and order of precedence.  Corrective action boards.  Nonconforming material management.  Using the material review function as a vehicle for forcing corrective action.  Evaluating corrective action efficacy.   Case studies.   

  • Module 7: Visual Manufacturing.  Visual manufacturing definitions.  The case for quality measurement and production status transparency throughout the organization.  Shop floor practices, including work-in-process inventory locations and levels.  Tooling shadow boards.  The 5S Program:  Sorting, simplifying, scrubbing, stabilizing, and maintaining self-discipline.  The “Mr. Clean” approach.  Dashboard reports and recommended dashboard metrics.  Case studies.  

  • Module 8:  Integrating Purchasing Activities.   Integrating supplier load versus capacity factors into your lean manufacturing philosophy.  Managing the external factory.  Timing supplier deliveries.  Assuring purchase order due dates support your manufacturing need times.   The “Wonder Bread” approach.  Reducing in-house supplier inventories in your facility.   Implementing and using a supplier quality and delivery rating program to drive supplier selection and performance.   Case studies.  

  • Module 9:  The Six Sigma Approach.  Six Sigma program definitions.  Quality program evolution into the Six Sigma concept.  Statistical considerations underlying the Six Sigma approach.   The Motorola and General Electric experience.   Six Sigma statistical methods.  Continuous improvement.  Process design and management.  Statistical process control.  Variability reduction.  Voice of the customer.  Design of experiments.   Case studies.  

  • Module 10:  Putting It All Together.  Selling the Lean Manufacturing philosophy internally and externally.  Recommended overall implementation approach.  Targeting quick initial successes.  Likely risk and conflict issues.  Recommended conflict resolution strategies.  Recommendation risk management strategies.  Overcoming resistance to change.    Course review and program conclusions.  

 

The above training can be customized to meet your requirements.

Need a guest speaker for an important luncheon or dinner meeting?  Please contact us.

Any questions?  Please call us at 909 204 9984 or contact us via email.

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