Details

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LEAN MANUFACTURING
Duration: 2 Days
Time: 9:00am to 5:00pm
Lunch Break: 1:00pm to 2:00pm

INTRODUCTION
This workshop must be attended if your operations need to become more responsive to your customer’s needs.  You will be introduced to the many concepts that fall under the umbrella of lean, more so you will also get tangible ideas that you can take back to work and implement. Lean is a process that can help you to substantially reduce inventories, Work-In-Process, required floor space, cycle times and lead times.  It can also dramatically improve quality connecting processes and people to allow errors to be caught faster.

OBJECTIVE
Upon completion of this program, participants should be able to:

• Understand and implement lean activities
• Able to identify wastes in the shop-floor- to generate lean project ideas
• Able to differentiate between value and non-value added activities in order to transform to become a lean organization
• Able to understand all the tools of Lean such as  Poka-Yoke, SMED, Jidoka, 5S, Pull System, Cellular Manufacturing, One-Piece Flow, JIT & many more

KEY CONTENT
Module 1: The History of Lean Transformation

• Introduction to Lean Manufacturing
• The history of TPS
• Craft Manufacturing to Mass Production
• Mass Production to Lean Manufacturing
• Traditional Steps of Manufacturing
• Objectives of Lean & Why is it Important to make this transformation

Module 2: The Lean Principles

• Just-In-Time (JIT)
• Value
• The Value Stream
• Flow System
• Pull & Kanban system
• Perfection

Module 3: Value Analysis

• Analysis Value versus non-value-added activities to make the transformation
• Muda, Mura, Muri
• Gemba-Gembutsu
• Identify and analyse Non-Value-added activities
• Identify and analyse value-added activities

Module 4:The Eight Wastes

• Identification and elimination of Muda
  • Transportation
  • Inventory
  • Motion
  • Over-production
  • Over-processing
  • Waiting
  • Defects
  • Non-Utilized Skill

Module 5: The Tools of Lean Manufacturing

• When and How to Use Lean Tools
  • 5S- Sort, Set in Order, Shine, Standardize, Sustain
  • Identification and elimination of Muda.
  • Jidoka- Autonomation, TPM
  • Poka-Yoke for Error Proofing
  • Takt-Time for Flow
  • Pull System, Kanban
  • Quick Changeover/ SMED- For Flexibility
  • Cell Concept

Module 6: Conclusion

• Getting started
  • Sample Case Studies
  • Change Agent
  • Projects

In-House Activity: One practical shop-floor session to tackle the 8 wastes. Participants are required to go down to work areas where lean is to be implemented (e.g. production floor, warehouse, etc.). The findings can be used to start some lean projects or kaizen activities after this training). This activity will open participant’s eyes to look for improvement opportunities and move towards a lean organization.

WHO SHOULD ATTEND?
Suitable for Supervisor, Executive and Manager Level.

METHODOLOGY
Informative presentation, Group discussion & Presentations, Real Case Studies & Video Presentations, Lean Simulations, Line Tours & Learnings for In-House.