Lean Manufacturing Training

Lean Manufacturing Training

Lean manufacturing is not new, dating back to the 20^th century when large-scale assembly line manufacturing was beginning and there was a need for efficiency, consistency and speed.

But it wasn’t until the Toyota Production System (TPS) introduced lean manufacturing into its production process that the business world began taking a serious look at lean manufacturing.

Today, many organizations either implement lean manufacturing or are considering it, especially in an era of rapidly rising manufacturing costs.

And it’s no wonder. Lean manufacturing has a plethora of benefits. In general a lean manufacturing approach should improve everything from lower levels of inventory to improved supplier relations.

Lean manufacturing is also used to:

• Improve delivery performance
• Develop better customer satisfaction
• Improve employee morale and involvement
• Improve quality performance with fewer defects and rework
• Initiate faster development
• Operate with fewer machines and process breakdowns
• Operate with less space required

A lean manufacturing approach often becomes a reality for organizations when overhead needs cutting or stakeholders insist on it.

It’s important to understand that implementing lean manufacturing may seem like a hassle at first, but lean manufacturing has considerable proven benefits, all of which should improve an organization’s bottom line.

What it comes down to is this: Lean removes waste. Waste is generally broken down into seven distinct areas:

• Transport
• Inventory
• Motion
• Waiting
• Over-Processing
• Overproduction
• Defects

All of these wastes have a direct impact on your costs, they are all non-value adding operations, operations that your customer would not be happy to pay for and add no value to the product or service that you provide.

Studies prove that we only add value for around 5% of the time within our operations, the remaining 95% is waste. Imagine if you could remove that 95% wasted time and effort, what would it do for your operations?

Lean Manufacturing Training Course by Tonex

Lean manufacturing training covers the concepts and techniques of Lean and Lean Management and that how you can apply those in your own business.

Lean manufacturing helps to provide more value for the customers at a lower cost and shorter time. Lean manufacturing cuts the extra steps between the customer order and delivering the product, resulting in faster delivery and less waste. Lean manufacturing training teaches you how to continuously seek out for waste resources and once they are found, how to eliminate them throughout the entire enterprise and chain value.

Why Do You Need Lean Manufacturing Training?

Every business activity is considered an operation system. Therefore, the concept of cutting out wastes can be applied to any activity in order to accomplish a greater performance.

Eliminating sources of waste will cause shorter time frame, lower costs, reduced inventory, greater quantity, and higher return on assets.

Added Value of Lean Manufacturing Training

• System performance
• Identifying the sources of waste and eliminating them
• Eliminating sources of variability
• In-depth understanding and applying of the fundamentals of operations management

What Industries Can Benefit from Lean Manufacturing Training?

• Chemical suppliers plants
• Energy
• Oil and gas
• Aerospace
• Steel
• Automotive
• Tire
• Plastics
• Furniture
• Computer
• Defense
• Logistics
• All manufacturing and businesses interested in improving the quality of their products, while reducing time, costs, and wastes.

Audience

Lean manufacturing training is a 2-day course designed for:

• Manufacturing and production engineers
• Manufacturing and production supervisors and managers
• Plant managers
• Purchasing personnel
• Supply chain personnel
• Quality control team
• R&D personnel
• Project managers
• Project engineer managers
• Senior and middle level management of small, medium and large scale companies
• Maintenance managers

Training Objectives

Upon the completion of lean manufacturing training course, attendees are able to:

• Understand the logic and concepts behind lean manufacturing
• Apply core tools of lean manufacturing in their business
• Adjust the techniques of lean manufacturing to their specific needs
• Value stream map the existing situation of their knowledge and resources flow through the chain of value
• Determine the sources of waste
• Identify the waste root causes in the value stream
• Derive a state vision for the future of their systems through Kaisens to remove the sources of waste by determining fresh paths to accomplish a non-stop flow through production units
• Effectively lead the lean initiatives
• Articulate different Lean tools and methods
• Understand Lean Metrics
• Understand Maturity Matrix

Course Outline

Overview

• Definition of lean manufacturing
• Lean definition
• Lean Management definition
• Historical origin of lean manufacturing
• Types of waste
• Lean Leadership
• What is TPS
• Lean Services, Goals and Strategies
• Lean implementation
• Lean Management System
• Lean journey
• Lean roots
• Lean benefits
• Lean impact on cash flow
• Potential increase in revenue
• Lean challenges and difficulties

Types of Waste

• The main sources of waste
  • Transportation
  • Inventory
  • Motion
  • Waiting
  • Over production
  • Defects
• Other sources
  • Underutilized skills
  • Wrong automation
  • Wrong metrics

Lean System Design

• Value Stream Mapping
• Design of pull
• Factory layout
• The physics of Lean
• Build to order

Supporting Lean Tools & Methods

• Cell assessment & design
• Implementing Kaizen Bursts
• Material handling
• Designing standardized work
• Lean rapid plant evaluation

Lean Tools

• 5S plus one
• Value stream mapping
• Kaizen
• Kaizen Blitz
• Seiri
• Seiton
• Seiso
• Seiketsu
• Safety
• Takt
• Jidoka
• Kanban
• Mistake proofing (Poka Yoke)
• SMED

Lean Management Lean Metrics

• FPY & RTY
• Inventory days
• Schedule adhere execution
• Lean accounting

Lean Maturity Metrics

• Evaluation process
• Evaluation standards
• Lean Maturity levels

Overview of Other Lean Techniques

• Lean in service
• Lean in office
• Theory of constraints
• Quick response manufacturing
• Physics of factory
• Six Sigma

Leadership & Team Management Tools & Methods

• Integrating Six Sigma in Lean systems
• Leading the change to Lean
• Accounting for Lean Manufacturing
• Developing & leading team works

Tonex Hands-On Workshop Sample

• Bringing in a project from your own organization or using a real case study that our instructors will provide
• Identifying the sources of waste
• Eliminating wastes process
• Evaluating the process and how effective it was
• Applying the Lean tools and methods learned during the course
• Comparing how your Lean process affected the costs, timing, and quality of the products with those before the Lean implementation

Lean manufacturing training