Lean Workshops

   Register for a Lean Workshop here...

Introduction to Lean Operations

This workshop presents procedures companies use to identify and eliminate waste to become lean. Tools used to identify and eliminate waste are highlighted in this workshop.

Workshop Objectives

After completion of this workshop you will be able to

¨      Explain what a lean operation is and the benefits it provides

¨      Identify waste activities and understand why they should be eliminated

¨      Analyze a process using process flow analysis approach

¨      Understand popular lean manufacturing tools such as the 5 Ss, visual order and control, setup time reduction, manufacturing cells, use of takt time, standard worksheets, etc.

¨      List the benefits of incorporating lean concepts during the development phase of 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.

Workshop Topics

¨      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 the tools for mapping a value stream. It gives a framework and provides practical step-by-step guidance to recognizing value streams and developing current state maps, future state maps, and the action plan.

Workshop Objectives

¨      To introduce the basic mapping tools for 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

Workshop Topics

¨      Types of map used for lean

¨      Value-stream mapping

¨      How to identify your company’s value streams

¨      How to create a current state map

¨      How to develop other useful maps

¨      How to analyze a current state map and develop a future state

¨      A framework for lean implementation using mapping

5 S Method

Workshop Objectives

¨      Learn the benefits of 5 S

¨      Understand the definition and meaning of 5 Ss

¨      Learn the proper strategy for implementing a 5 S program

¨      Conduct 5 S exercises

¨      Apply 5 S principles at work

5 S Workshop Topics

¨      introduction to lean manufacturing

¨      goal: learn 5 S by doing

¨      definition of the 5 S

¨      Phase 1 of 5 S: Sort

¨      (Note: there are five group exercises in a traditional workshop environment that the participants will be called upon to complete as part of a 4 -5 person team)

¨      Exercise 1 – tackle disorderliness and lack of cleanliness and sorting in the shop by targeting unneeded and excess items

¨      discuss sorting observations/opportunities for implementing 5 S projects

¨      auditing a shop for sort

¨      Phase 2 of 5 S: Set in order/ Simplify

¨      Exercise 2 - develop a new layout for the shop to include material, equipment and fixtures, and location indicators

¨      discuss set in order observations/opportunities for implementing 5 S projects

¨      auditing set in order

¨      Phase 3 of 5 S: Shine/ inspect

¨      Exercise 3 - identify and develop a plan for shop cleaning and equipment inspection/maintenance

¨      auditing shine/inspect

¨      Phase 4 of 5 S: Standardize

¨      auditing standardize

¨      Exercise 4 - identify and develop a plan on how to standardize the 5 S program within the plant

¨      discuss standardize observations/opportunities for implementing 5 S projects

¨      Phase 5 of 5 S: Sustain

¨      auditing sustain

¨      Exercise 5 - identify and develop a plan on how the plant can sustain the 5 S program

¨      discuss sustain observations/opportunities for implementing 5 S projects

Process Improvement and Lean Quality

Improvement and quality are at the heart of lean. This workshop discusses the PDCA and DMAIC (six sigma) frameworks and the concepts of kaizen, root cause problem solving, the visual factory, the seven tools of quality, and blitz approaches. An improvement framework and sustainability of improvement are discussed.

Workshop Objectives

¨      To illustrate the symbiotic relationship between lean and quality

¨      To appreciate the application of some quality techniques in a lean context.

¨      To appreciate how lean and six sigma can work together.

Workshop Topics

¨      Views from the Gurus

¨      The Lean View and Kaizen

¨      Problem Solving and PDCA

¨      Types of Defect

¨      Sporadic Problems: The Seven Tools and Five Whys

¨      Chronic Problems and Six Sigma

¨      Improvement Types

¨      Improvement Events (Blitz)

¨      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 kanbans, heijunka, and mixed-model production.

Workshop 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.

¨      Workshop Topics

¨      Frameworks for lean scheduling

¨      Relationships between lean and MRP, APS, and TOC

¨      Managing queues and flow

¨      The effects of variation (statistical fluctuation and dependent events)

¨      Building blocks for lean scheduling

¨      Eight lean scheduling ideas: (pull and kanbans, takt time, runners repeaters strangers, the pacemaker, mixed model scheduling, level scheduling and heijunka, batch sizing, demand stabilization)

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.

Workshop 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

¨      Workshop 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.

Workshop Objectives

¨      To provide an 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

Workshop Topics

¨      Team and Leadership Models for Lean

¨      Lean Measurements

¨      Lean Accounting and Costing

¨      Lean Design Considerations

¨      Modularity and Platforms