Lean Manufacturing

Introduction

This workshop must be attended if your operations need to become more responsive to your customer’s needs. You will be introduced to the many concepts that fall under the umbrella of lean. More so, you will also get tangible ideas that you can take back to work and implement. Lean is a process that can help you to substantially reduce inventories, work-in-process, required floor space, cycle times and lead times. It can also dramatically improve quality by connecting processes and people to allow errors to be caught faster.

Course Objectives

Upon completion of this program, participants should be able to:

• Understand and implement lean activities
• Identify wastes in the shop-floor to generate lean project ideas
• Differentiate between value and non-value-added activities in order to transform into a lean organization
• Understand all the tools of lean such as Poka-Yoke, SMED, Jidoka, 5S, Pull System, Cellular Manufacturing, One-Piece Flow, JIT and many more

Key Content

Module 1: The history of lean transformation

• Introduction to lean manufacturing
• The history of TPS
• Craft manufacturing to mass production
• Mass production to lean manufacturing
• Traditional steps of manufacturing
• Objectives of lean and why it is important to make this transformation

Module 2: The lean principles

• Just-In-Time (JIT)
• Value
• The value stream
• Flow system
• Pull & Kanban system
• Perfection

Module 3: Value analysis

• Analyse value versus non-value-added activities to make the transformation
• Muda, Mura, Muri
• Gemba-Gembutsu
• Identify and analyse non-value-added activities
• Identify and analyse value-added activities

Module 4: The eight wastes

• Identification and elimination of Muda
  • Transportation
  • Inventory
  • Motion
  • Over-production
  • Over-processing
  • Waiting
  • Defects
  • Non-Utilized Skill

Module 5: The tools of lean manufacturing

• When and How to Use Lean Tools
  • 5S- Sort, Set in Order, Shine, Standardize, Sustain
  • Identification and elimination of Muda.
  • Jidoka- Autonomation, TPM
  • Poka-Yoke for Error Proofing
  • Takt-Time for Flow
  • Pull System, Kanban
  • Quick Changeover/ SMED- For Flexibility
  • Cell Concept

Module 6: Conclusion

• Getting started
  • Sample case studies
  • Change agent
  • Projects

In-House Activity

One practical shop-floor session to tackle the 8 wastes. Participants are required to go down to work areas where lean is to be implemented (e.g., production floor, warehouse, etc.). The findings can be used to start some lean projects or kaizen activities after this training. This activity will open participants’ eyes to look for improvement opportunities and move towards a lean organization.

Target Audience

Suitable for Supervisor, Executive and Manager level.

Methodology

Informative presentation, group discussion & presentations, real case studies & video presentations, lean simulations, line tours & learnings for in-house.