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LEAN IMPLEMENTATION WORKSHOP (FOR MANUFACTURING INDUSTRY) COURSE CODE: MGT/10
Course Description:
Lean techniques were first introduced by the Toyota Motor Corporation around 1990 and since then have been used by major corporations to reduce operating time and costs while retaining product quality. Lean techniques evolve into operating philosophies to: make only what you need, never make a defect or pass a defect on, eliminate waste, and focus on cycle time reduction which ultimately reduces costs. Once in place, lean systems use less people, space, inventory, and financial investment. This course teaches you the benefits of LEAN and how it can apply to your work situation.
This two-day workshop demonstrates the principles and concepts of Lean Manufacturing through lectures and multiple hands-on simulations. It is also intended to provide management staff and employees at all levels of your organization with a basic understanding of Lean Implementation, and the benefits to be gained.
Course Objective:
- Understand the terms, terminology, and benefits of Lean Manufacturing.
- Conduct value stream maps of the current state, identify the potentials for reduced waste and improved flow, and develop a future state map.
- Participate in the development of a site-specific lean implementation roadmap.
- Avoid the common pitfalls encountered during lean implementation.
Course Outline:
Day 1 Content
- Overview of the Lean Manufacturing process, performance goals and critical success factors
- Comparison of Lean vs. Traditional Manufacturing
- Definition of Key Concepts
- Overview of Lean tools and techniques:
Value Stream Mapping / Seven Muda / Pull System / Takt Time / Poka-yoke / Kanban Quick / Quick Changeover or SMED / Total Predictive Maintenance (TPM) / Standardized Work / Visual Management / 5S etc.
Day 2 Content
- Selection of a high level Lean initiative
- Why Systems Thinking is a critical component of a Lean initiative
- How to develop a Lean culture in your company
- Lean implementation in your company - how to develop the plan
- Project prioritization and preparation
- Case Studies of Lean Application
Who Should Attend:
Participants can be from any industry and at any level who may be directly involved or in the process of being involved in a specific Lean project or organization-wide Lean change program, or have been asked to contribute as part of a Lean team.
About the Facilitator:
The facilitator has 20 years local and regional experience in process improvement and quality management in both manufacturing and service industries. He has worked on many in house Lean consultation projects in multinational and local companies. He is also a Certified Six Sigma Master Black Belt and currently one of the examiners of International Six Sigma Council (ISSC). He holds a doctorate degree in Engineering Management. The tutor has incorporated Lean & Six Sigma practices into an organization by applying relevant lean tools such as VSM, waste reduction to achieve a lean result. To name a few about the project, it includes inventory reduction of 20%, lead time reduction of 60% and delivery performance improvement of 30%.
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