WHAT THE COURSE COVERS:

• Section I Why Lean Manufacturing? Why go Through the Pain of Change?
• Traditional Manufacturing Operating Systems
• Lean Benefits for Competitive Advantage
• Modern Planning Systems vs. Lean Operating Systems
• Planning Systems Impact on the Bottom Line
• Re-Thinking the Planning System Model
• We Want to Change, But How?
• Taking a Disciplined Approach to Change



• Section II The Lean Manufacturing Model
• Producing Product in the Work Content Time
• TAKT Line Balancing & Design
• Kanban Material Strategies to Support the Lean Advantage
• Sequencing Production One Piece at a Time
• Benefits of a Lean Operating System
• Lean Manufacturing Challenges to the Planning Paradigm
• Supply Chain Management, RFID, and E-Commerce Technologies



• Section III Understanding Your Products, Processes, and Demand
• Selecting Parent Parts Candidates for the Lean Line
• Establishing Capacity to Meet Volume Demands for the Lean Implementation Area
• Documenting the Process Flow and Establishing Mixed Product Families
• How Scrap, Rework and Optionality Affect Throughput Volume
• Establishing Multi-Product Families
• Identifying Process Demand Levels and Establishing TAKT
• Documenting Work Elements and Quality Criteria with the Sequence of Events
• Non-Value Added Activity and Quality Considerations


WORKSHOP # 1 Calculate TAKT Time, Standard Time Weighted, and Resources


• Section IV Line Layout, Workstation Identification with Process Linking and Balancing
• Identifying Resources
• The Consequences of Factory Imbalance
• How Lean Achieves Balance in a Factory
• Determining Resource Requirements Necessary to Meet Demand
• Types of Different Resources for The Lean Line
• The Physical Layout of Resources
• Assigning Tasks for Each Workstation
• The In-Process Kanban Signaling Methodology
• Disciplines for Maintaining Workstation Balance

END of DAY 1

Workshop Discussion: Case Studies and Variation from the Norm
A classroom segment devoted to discussing unique situations and modified applications of Lean Manufacturing Methodologies to special products, process and industries. Examples include process industries, lot size constraints, high volume, low volume, product size considerations (large & small), and resource size and travel distances. Students are encouraged to address any special circumstances of their own product or process environment during this discussion so all delegates present can learn special application of the Lean Manufacturing techniques that can be used for their own manufacturing facility.


• Section VI The Kanban Strategies
• Advantages & Disadvantages of Kanban Systems
• The Single-Card Kanban System
• Pull Chains, Replenishment Times, and System Setup and Daily Operation
• Kanban Sequencing of One-Time Use Parts
• The Multiple-Card Kanban System
• The Wait/Work Sequencing Board
• Managing Inventory with the Kanban System
• The Kanban System and Supply Chain Management


WORKSHOP # 2 Develop Pull Chains, Establish Replenishment Times, Calculate Kanban Quantities, and Manage Inventory Investment and Turn Rate


• Section VII Managing the Lean Manufacturing Line
• Determining Critical Path Through Manufacturing
• Sub-optimizing the Lean Line to Meet Daily Rate of Demand
• The Flexible Employee System
• Employee Reward Systems to Encourage Participation
• Establishing Customer Response Policy- One Size Does Not Fit All
• Graphic Work Instructions
• The Supplier Certification Program And Its Importance to Supply Chain Management
• Sequencing Demand to the Line
• New Performance Measurements and the Standard Cost Accounting System



• Section VIII Managing the Transformation Project
• The Strategic Business Analysis- Determining the ROI on Implementation
• Justifying the Effort for Change
• Making the Commitment to Change- Are You Ready Willing and Able to Change?
• Documenting Current Performance Metrics
• Do Productivity Improvement Programs Really Work?
• Lead Time- A Self-Fulfilling Prophecy of Working Capital
• The Transformation Process
• Project Management Structure-Steering and Implementation Teams
• The Lean Implementation Milestones Checklist
• Starting the Line Up
• Organizational Impacts of Lean Manufacturing


WORKSHOP # 3 Calculate Resources, Complete Facility Layout, Present Line Design to Class
END of DAY 2