Price: $1,699.00

Length: 2 Days
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Lean Manufacturing Training

The core idea behind lean manufacturing is to maximize customer value while minimizing waste, according to the Lean Enterprise Institute.

The business benefits of lean are achieved because there’s less process waste, reduced lead time, less rework, reduced inventories, increased process understanding, improved knowledge management and lower costs.

Manufacturing is the fourth largest industrial sector in the United States, currently employing about 15.6 million Americans, representing about 11% of the gross domestic product, according to manufacturing.gov.

So it should come as no surprise that organizations have been trending toward lean manufacturing principles to eliminate waste, optimize processes, cut costs, boost innovation and reduce time to market.

Organizations that focus on lean manufacturing understand customer value and focus key processes to continuously increase it. The ultimate goal is to provide perfect value to the customer through a perfect value creation process that has zero waste.

How is this accomplished?

A lean manufacturing approach should take management from optimizing separate technologies, assets, and vertical departments to optimizing the flow of products and services through entire value streams that flow horizontally across technologies, assets and departments to customers.

Eliminating waste along entire value streams, instead of at isolated points, creates processes that need less human effort, less space, less capital, and less time to make products and services at far less costs and with much fewer defects, compared with traditional business systems.

Organizations are then in a position to better respond to changing customer desires with high variety, high quality, low cost, and with very fast throughput times.

Additionally, information management becomes simpler and more accurate.

With benefits come challenges. Three common challenges encountered with a lean manufacturing approach are:

  1. Cost: Mistake proofing processes will cost money. Fixing problem areas permanently will usually cost money. Redesign of equipment to facilitate new line balancing will cost money. But over time, these improvements will pay for themselves through increased quality and reduced defects.
  2. Maintenance: An effective lean approach requires some upkeep. Levelized production requires regular updating and maintenance. With proper execution in the general labor area, you should be able to free up people to fill these roles.
  3. Resistance to Change: It’s common for teams in an organization to enjoy living in their comfort zones. But sometimes change is the best path for moving forward. Through training, people in your company should be made aware of what is coming, why it is happening and how the company and its employees will benefit from the changes.

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 training

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

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