Module 1 |
Introduction |
Manufacturing background; The history of lean manufacturing; Lean thinking; Waste; Introduction to the philosophy and tools of lean manufacturing; Lean audits |
Module 2 |
Layout, Cell Design Changeover Reduction |
Types of layout; Cell design principles and exercise; Line balancing; Work analysis tools; SMED techniques; SMED Exercise |
Module 3 |
5S and TPM |
5S and autonomous maintenance; The 5S implementation model; Visual management; OEE; The TPM implementation model; Planned maintenance |
Module 4 |
Quality, Problem Solving, Continuous Improvement |
Fundamental concepts; Problem solving; The seven quality tools; Standard work; Poka yoke; TRIZ; Introduction to SPC; Process capability; Six Sigma; Kaizen |
Module 5 |
Scheduling |
Demand management; MRP and lean; Capacity and queues; The dice game; Theory of constraints; Lean scheduling; Kanban and CONWIP |
Module 6 |
Lean Supply and Teamwork |
Team leadership; Motivation, communication, conflict resolution; Case studies; Supply chain development; Lean supply; Supplier development; The lean enterprise |
Module 7 |
Lean Design, Lean Measures and Lean Accounting |
Principles of lean design; Value engineering; Measures for lean; Lean accounting; Throughput, performance measurement and lean indicators |
Module 8 |
Value Stream Mapping 1 |
The use of value stream mapping; Elements of the value stream mapping tool; Drawing the current state map; Case exercise |
Module 9 |
Value Stream Mapping 2 and Process Mapping |
Creating the future state map; Devising an action plan; Introduction to effective process mapping concepts |
Module 10 |
Implementation, Policy Deployment and Culture |
Leading change on the factory floor; Hoshin planning; Overcoming implementation barriers; Organising for lean transformation; Kaizen Blitz
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