Lean Production Methodologies and Techniques

The core idea of lean manufacturing is actually quite simple…relentlessly work on eliminating waste from the manufacturing process. 

This two day participative workshop introduces key methodologies and techniques aimed to improve operational effectiveness from within. These concepts and principles will be described and put in context to explain how they can be applied in the client workplace. 

Description

The core idea of lean manufacturing is actually quite simple…relentlessly work on eliminating waste from the manufacturing process. 

This two day participative workshop introduces key methodologies and techniques aimed to improve operational effectiveness from within. These concepts and principles will be described and put in context to explain how they can be applied in the client workplace. 

How will this Workshop be Presented?

This workshop combines theory and practice. We use company examples to illustrate how the techniques presented have been applied in real case studies. The purpose is to use a mix of proven learning techniques to ensure maximum understanding, comprehension and retention of the information presented.

The Course Content

DAY 1

Introduction to Lean Six Sigma 

  • Concepts, philosophy, and benefits of Lean Six Sigma 
  • Lean Production and Total Quality Management (TQM) 
  • Lean Six Sigma  roles, responsibilities, and project selection  
  • ‘DMAIC’ (Define, Measure, Analyse, Improve, and Control 

 Continuous Improvement, Waste Elimination, and Customer-Focused Quality 

  • Fundamentals of Continuous Improvement 
  • Finding and Implementing Improvements – PDCA, ”5 Whys”, Kaizen 
  • Value Stream Mapping 
  • Value Added Focus 
  • Sources of Waste – Toyota’s Seven Wastes/Canon’s Nine Wastes 

 

DAY 2

Elements of Lean Production 

  • Meaning of Lean Production 
  • Small Lot Production 
  • Economic Order Quantity (EOQ) Methods 
  • Set-up Time Reduction Methodology – Shingo and SMED 
  • Techniques for Set-up Reduction 

Pull Production Systems 

  • Pull versus Push, or both together? 
  • Achieving Pull Production  
  • Kanban options 
  • Mechanisms for Signal and Control 
  • Pull – drawbacks and limitations 
  • Production Levelling 
  • Mixed-Model Production 

Balancing the Process 

  • Synchronised Cycle Times 
  • Bottleneck Scheduling 
  • Line Balancing 

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