"Lean Manufacturing Workshop Series Developing Lean Manufacturing"
Lean Manufacturing Workshop Series Developing Lean Manufacturing Strategies Lean Manufacturing - “A philosophy of production that emphasises the minimisation of the amount of all the resources used in the various activities of the enterprise. It involves identifying and eliminating non-value-adding activities in design, production, supply chain management and dealing with customers. Lean manufacturers employ teams of multiskilled workers at all levels of the organisation and use highly flexible, increasingly automated machines to produce volumes of products in potentially enormous variety. It contains a set of principles and practices to reduce cost through the relentless removal of waste and through the simplification of all manufacturing and support processes.” APICS Dictionary. This series consists of 7 one-day workshops. The workshops that make up this series are: Introduction to Lean Manufacturing Lean Mapping 5S Process Improvement & Quality in Lean Manufacturing Lean Scheduling Standard Work Lean Teams, Lean Design and Accounting INTRODUCTION TO LEAN MANUFACTURING This workshop presents procedures companies use to identify and eliminate waste to become lean. It also covers a variety of tools that are used and covers such topics as the transparent workplace, lean process improvement, lean product development, Just-in-Time, controlling processes, and continuous improvement. At the completion of this workshop you will be able to: - Explain what a lean operation is and benefits it provides - Identify waste activities and understand why they should be eliminated - Analyse a process using process flow analysis approach - Understand popular lean manufacturing tools such as the 5Ss, visual order and control, setup time reduction manufacturing cells, use of takt time, standard worksheet etc - List the benefits of incorporating lean concepts during the development phased of the new products - Explain what error-controlling devices are and how they can be used during production to reduce errors - Understand what sigma quality concepts are, how to conduct kaizen blitzes and why continuous improvement is important. Topics covered: Waste elimination A lean improvement methodology Leadership The transparent workplace Lean process improvement Lean product development Just-in-time Controlling processes Standard work Continuous improvement LEAN MAPPING This workshop provides seven basic tools for mapping a value stream. It gives a framework and provides practical step-by- step guidance to recognising value streams and developing current-state maps, future-state maps and the action plan. Objectives: - To introduce the basic mapping tools to lean analysis - To understand when and how various mapping tools could be used - To obtain a grounding on learning-to-see mapping - To learn how mapping can be the basis of lean transformation Topics: Types of maps used for lean Value-stream mapping How to identify your company’s value-streams Ho to create a current state map How to develop other useful maps How to analyse a current state map and develop a future state A framework for lean implementation using mapping 5S The 5 S method detailed in this workshop provides a foundation for delivering high quality products and services in the right quantity at the right time to satisfy customer needs. The 5 S method is a perfect starting point for companies to begin their journey toward lean as well as an intermediate step to emphasize the value of workplace organisation and process discipline. Objectives: - Learn the benefits of 5S - Understand the definition and meaning of 5S - Learn the proper strategy for implementing a 5S program - Conduct 5S exercises - Apply 5S principles at work Topics: Introduction to lean manufacturing Auditing set in order Goal: 5 S by doing Phase 3 of 5 S: Shine/inspect Definition of the 5 Ss Exercise 3: Identify and develop a plan for shop Phase 1 of 5 Ss: Sort cleaning & equipment inspection/maintenance Exercise 1: Tackle disorderliness and lack of Auditing shine/inspect cleanliness and sorting the shop by targeting Phase 4 of 5 S: Standardise unneeded and excess items Auditing standardize Discuss sorting observations/opportunities for Exercise 4: Identify and develop a plan on how implementing 5S projects to standardize the 5 S program within the plan Auditing a shop for sort Discuss standardise observations/opportunities Phase 2 of 5 S: Set in order for implementing 5 S projects Exercise 2: Develop a new layout for the shop Phase 5 of 5: Sustain to include material, equipment and fixtures Auditing sustain and location indicators Exercise 5: Identify and develop a plan on how Discuss set in order the plant can sustain the 5 S program observations/opportunities for implementing 5 Discuss sustain observations/opportunities for S projects implementing 5S projects PROCESS IMPROVEMENT & QUALITY IN LEAN MANUFACTURING This workshop documents the steps of implementing Process Improvement and Quality in Lean Manufacturing – a tool to determine maximum performance with minimum waste through the best combination of operator and machine. Process Improvement and Quality in Lean Manufacturing helps eliminate variability from the process, functions as diagnostic device, and exposes problems to facilitate problem solving. Objectives: - To illustrate the symbiotic relationship between lean and quality - To appreciate the applicant of some quality techniques in a lean context - To appreciate how lean and six sigma can work together Topics: Views from the gurus The lean view of kaizen Problem solving & PDCA Types of defect Sporadic problems: the seven tools and whys Chronic problems and six sigma Improvement type Improvement events Holding the gains and sustainability LEAN SCHEDULING This workshop covers the essential tools for lean scheduling. After discussing the relationships with MRP II, APS, and factory physics, the workshop describes six building blocks and eight lean scheduling methods including kanban, heijunka and mixed- model production. Objectives - Provide an overview of the central role of scheduling in a lean context - Establish a framework for the implementation of a lean scheduling system - Provide a working knowledge of core lean scheduling techniques Topics Framework for lean scheduling Relationships between lean and MRP, APS and TOC Managing queries and flow The effects of variation (statistical fluctuation and dependent events) Building blocks for lean scheduling Eight lean scheduling ideas: (pull & kanban, takt time, runners repeaters strangers, the pacemaker, mixed model scheduling, level scheduling and heijunka, batch sizing, demand stabilization) A brief look at CONWIP and POLCA STANDARD WORK This workshop documents the steps of implementing standard work—a tool to determine maximum performance with minimum waste through the best combination of operator and machine. Standard work helps eliminate variability from the process, functions as a diagnostic device, and exposes problems to facilitate problem solving. Objectives: - Understand the elements and methods of standard work - Understand cellular manufacturing - Conduct time observations, process capacity studies and team activities related to standard work - Prepare standard work documents Topics: Introduction to standard work Capacity concepts Cellular manufacturing Standard work elements LEAN TEAMS, LEAN DESIGN AND ACCOUNTING This workshop examines the correlation between teams, design and accounting in lean manufacturing. Lean team types, leadership skills and anchor draggers are discussed. Lean design covers concurrent design, value engineering, QFD and FMEA. Objectives: - To provide and overview of the role teams, measurements and design have in contributing to success in lean implementation - To review relevant current theories on teams, accounting and design as they relate to lean Topics: Team and leadership models for lean Lean measurements Lean accounting and costing Lean design considerations Modularity and platforms