Length: 2 Days
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RCA in Lean Manufacturing Workshop by Tonex

Certified Lean Design Engineer for Manufacturing & Assembly (CLDeMA) Certification Course by Tonex

The Root Cause Analysis (RCA) in Lean Manufacturing workshop by Tonex provides participants with the tools and techniques needed to identify the root causes of problems and implement effective solutions in a lean manufacturing environment.

Learning Objectives:

  • Understand the principles of RCA in the context of lean manufacturing.
  • Learn to identify and analyze root causes of issues.
  • Develop skills to implement effective corrective actions.
  • Understand the integration of RCA with lean tools and methodologies.
  • Gain insights into continuous improvement and problem-solving strategies.
  • Learn to document and communicate RCA findings effectively.

Audience:

  • Lean Manufacturing Practitioners
  • Quality Assurance Professionals
  • Process Engineers
  • Production Managers
  • Maintenance Personnel
  • Continuous Improvement Teams

Program Modules:

  1. Introduction to Lean Manufacturing and RCA
    • Overview of lean manufacturing principles
    • Importance of RCA in lean manufacturing
    • Key concepts and terminology
    • Benefits of combining lean and RCA
    • Overview of common lean tools
    • Case studies in lean and RCA integration
  2. Root Cause Analysis Techniques
    • Basics of root cause analysis
    • Common RCA tools and techniques
    • Fishbone diagram (Ishikawa)
    • 5 Whys analysis
    • Pareto analysis
    • Fault tree analysis (FTA)
  3. Problem Identification and Data Collection
    • Identifying problems and defining the scope
    • Data collection methods and tools
    • Analyzing data to identify patterns
    • Use of statistical tools in RCA
    • Creating a problem statement
    • Case studies in problem identification
  4. Implementing Corrective Actions
    • Developing effective corrective actions
    • Prioritizing actions based on impact
    • Implementation planning and execution
    • Monitoring and verifying effectiveness
    • Preventive measures to avoid recurrence
    • Continuous improvement strategies
  5. Integration with Lean Tools
    • Combining RCA with value stream mapping (VSM)
    • Use of Kaizen and RCA
    • Applying RCA in 5S and standard work
    • RCA in Total Productive Maintenance (TPM)
    • Lean Six Sigma and RCA integration
    • Case studies of successful integration
  6. Documentation and Communication
    • Documenting RCA processes and outcomes
    • Creating RCA reports and presentations
    • Communicating findings to stakeholders
    • Training teams on RCA methods
    • Best practices for knowledge sharing
    • Continuous learning and improvement

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