Overview

LEAD® Lean Manufacturing workshop provides participants with the basic Lean concepts and principles. These concepts and principles will be described and put in context to explain how they can be applied within the manufacturing environment.

Lean is simply about creating more value for customers by eliminating activities that are considered waste. Any activity or process that consumes resources, adds cost or time without creating value becomes the target for elimination. One of the important aspects of Lean is the focus on 'system-level' improvements (versus 'point improvements'). It's the system-level work that can dramatically improve a company's bottom line results. This knowledge, combined with the understanding of how to remove waste properly, is critical for any successful Lean implementation.

Common Lean improvement tools and techniques will be identified and the class will discuss how best to apply these techniques from a Lean system perspective. The common mistake companies make by focusing on 'point' improvements versus 'system' improvement will be studied - 'point' improvements creating 'exciting chaos' and 'system' improvement creating dramatic bottom line improvements.

Different types of Waste will be defined from a Lean point of view. Class will brainstorm, identify and classify the different types of waste that they see within their own work environments. Identifying waste is the first necessary step. Knowing how to properly remove it, is much more challenging. The root causes of Waste will be examined and successful methods used to eliminate it will be discussed.

A group simulation will demonstrate the power of one-piece flow (vs. batch production). This workshop will briefly discuss other key factors within an organization necessary to sustain Lean. An examination of the company organization; the leadership and culture, common company measures will be studied in terms of how they reinforce present behaviors and alternative Lean measures will be introduced.

Workshop Methodology

Pre-training assessment will be carried out for the participating companies. Participants will be stimulated to participate with active interaction in hands-on and practical team activities like business simulation, group discussions & presentations, and case studies.

What You Will Learn

Overview of Lean Manufacturing

• How the LEAN Concept Initiated and Evolved
  • The origin of Lean
  • Toyota Production System and Lean Manufacturing
• The Difference between LEAN and Traditional Manufacturing Concept
  • Why organization needs Lean Manufacturing today?
  • Benefits of implementing Lean in your organization
• How Lean can Help Your Organization to Improve Your Productivity, Costs, Quality and Delivery
  • Case study: Lean success stories
• Understand What ‘Value’ and ‘Waste’ in Manufacturing Are
  • How do you define waste
  • What is the real value of your products/ services to your customers
• Identification and Elimination of Waste
  • Activity: Waste hunting session
  • Seven wastes in your organization
  • Prioritize which wastes to eliminate based on the voice of customer
• Lean Simulation
• Lean Tools Box - A brief introduction to important Lean to
  • Visual Workplace Management,
  • Setup Reduction,
  • Total Productive Maintenance,
  • Error Proofing,
  • Lean Project Management and Business Case,
  • Kanban Pull System,
  • Theory of Constraint,
  • Lean Performance Metrics and
  • Hoshin Kanri Planning.

Value Stream Mapping

• Voice of Customers (VOC)
  • What is VOC?
  • Why VOC is so important
  • How do you collect the VOC
• Value Stream Mapping
  • What is value stream mapping
  • The important role of value stream mapping
• Product Families Selection
  • Product categorization matrix
  • Product families grouping
• Create The Current State Map
  • Material and information flow
  • The value stream manager
  • Using the mapping tool
  • Activity: Drawing the current state map
• What is a Lean Value Stream?
  • Overproduction
  • Characteristics of a lean value stream
• Create the Future State
  • Activity: Drawing the future state map
• Kaizen
  • The kaizen process
  • Utilizing kaizen tools
• Create a Improvement Roadmap
• Lean Leadership & Culture Change