Lean Manufacturing Course A-B Tech and Eaton Electrical Group
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Lean Manufacturing Course Agenda
(March 13-17, 2006 )
Enka Campus, Hayes 128
Each module is 3 and ? hours . Total course length is 3 7.5 hours. Morning session is 8:30 am to noon. Afternoon session is 1:00 pm to 4:30 pm.
This is an overview course for the Lean Manufacturing discipline. It focuses on the tools, techniques, concepts and principles of Lean. While most of the emphasis is on the manufacturing environment, examples from administrative functions are also used to explain key concepts. This is not a course on the leadership and management roles and responsibilities required to successfully implement Lean. Lean implementation is a MAJOR change initiative and as such, senior leadership must be completely committed to achieve success. All “best practices” in leading significant change efforts apply to Lean; however, this is not a course on leading major change initiatives. Participants will need to seek that knowledge elsewhere.
Module 1: Introduction to Lean and Factory Simulation (short version)
Day 1: Morning Session
This is an introduction to the basic principles and concepts of Lean Manufacturing. Instructors will lead participants through a basic factory simulation (hands-on) that will demonstrate how Lean can be used to dramatically improve productivity. Topics include:
a. An overview of Lean principles/concepts/tools.
b. The 7 Wastes, their causes and the effects.
c. Stockless Production (Video from HP)
d. Factory simulation (hands-on, short demonstration)
Module 2 : The Tools of Lean Manufacturing : Overview
Day 1: Afternoon Session
The Lean tools explored throughout the remainder of the course are introduced in this module. The SME video, Lean Production at Miller SQA , will be used to introduce this module. In addition to the video, presentation topics include:
a. Value Stream Mapping (VSM).
b. 5S.
e. Pull Systems.
c. Standardized Work.
d. Continuous Flow.
. f. Error Proofing.
g. Setup Reduction.
h. Total Productive Maintenance (TPM).
Module 3 : Learning to See : Value Stream Mapping – Current State
Day 2: Morning Session
Participants will learn the basics of Value Stream Mapping (VSM) and then will apply these concepts to build a Current State Map. This module is based on the Workbook, Learning to See, by the Lean Enterprise Institute. VSM is a tool that helps people to see and understand the flow of material and information as a product makes its way through the value stream. The SME video, Mapping Your Value Stream, will be used during this module. In addition to the video, topics include:
a. Preparation for building a Current State Value Stream Map.
b. How to build a Current State Map (principles, concepts, loops, and methodology).
c. Application to the factory simulation scenario.
Module 4 : Factory Simulation Phase 1: Initial Configuration and Current State Mapping
Day 2: Afternoon Session
The entire module is devoted to conducting the first phase of a factory simulation. Participants will use everything learned so far in the course to conduct a pre-set factory simulation, determine data requirements for process analysis, set up and execute a data collection plan, analyze the data, and construct a Current State Map of the Phase 1 process configuration. Participants will draw heavily upon the techniques studied in the Learning to See workbook from Module 3. The Current State Map developed in this module will be used as the jumping off point for subsequent modules and for Phase 2 and 3 of the factory simulation.
Module 5 : 5S and Pull Systems
Day 3: Morning Session
5S is the foundation for a disciplined approach to improving and standardizing the physical condition of the work areas (shop floor as well as front office). Participants will learn the concepts of 5S and effective implementation techniques. Topics include:
a. 5S – Sort.
b. 5S – Straighten.
c. 5S – Shine.
d. 5S – Standardize.
e. 5S – Sustain.
f. Implementation of 5S.
The SME videos, Kanban System s and Lean Tooling in Action, will be used in the exploration of Pull Systems. The focus of this portion of the module will be on changing from a PUSH process to a PULL process so that you make only what the customer is pulling from your production system. Topics include:
a. Pull versus Push production systems.
b. The key elements of Pull Systems.
c. Pull System – Kanban (4 types)
d. Pull System – Load Leveling
Module 6 : Standard ized Work and Continuous Flow Manufacturing
Day 3: Afternoon Session
The Standardized Work materials focus on designing the optimum combination of operators, machines and materials to ensure that production tasks are completed the same way every time with minimum waste. In the Continuous Flow materials, participants will learn how manual and machine operations can be linked to increase efficiency while minimizing transport and delay. These concepts will then be used to explore a step-by-step approach to design and implement a flow line (cell). The SME video, The Visual Factory, will be used in this module. In addition to the video, topics include:
a. Standardized Work Flow concepts.
b. Documenting and sustaining standard work practices.
c. Implementation techniques for Standardized Work.
d. Concepts and principles in setting up and implementing a continuous flow line (cell).
Module 7 : Learning to See : Value Stream Mapping – Future State
Day 4: Morning Session
This module is based on the workbook, Learning to See, by the Lean Enterprise Institute It introduces the principles and techniques used in building a Future State Map. Topics include:
a. Key questions in building the Future State Map.
b. Process tips in building the map and analysis of the customer loop, supplier loop, manufacturing loop and information loop that make up the map.
c. Example of completed Future State Maps.
d. Application to factory simulation.
Module 8 : Factory Simulation Phase 2 and 3 -- Future State VSM.
Day 4: Afternoon Session
This module builds on the Learning to See modules and on Phase One of the factory simulation introduced in Module 5 of the course. The simulation requires the participants to use all the tools and concepts that they’ve learned about Lean up to this point to develop the Future State Value Stream Map based on the already developed Current State Map and on the process analysis done through the use of the lean tools. The participants will:
a. Conduct an analysis of all the data developed during the development of the Phase 1 Current State Map.
b. Based on the analysis, build a Future State VSM for Phase 2 of the simulation as directed by the instructor, implement, collect data, analyze and present.
c. Based on the outcome of Phase 2, develop a final Future State VSM (Phase 3), re-run the simulation, collect data, analyze and report findings.
Module 9 : Error Proofing and Setup Reduction
Day 5: Morning Session
The Error Proofing materials in this module, including the SME video, Mistake Proofing, provide a systematic approach to preventing potential defects from reaching the customer. Topics include:
a. Understanding error proofing concepts and principles.
b. How to apply error proofing to products and processes.
c. Poka Yoke devices and systems.
d. How to implement and continuously improve error proofing.
In the Setup Reduction materials, which include the SME video, Quick Changeover for Lean Manufacturing , participants will learn a 5-step approach to identifying opportunities for and drastically reducing equipment setup time. Emphasis will be on how Setup Reduction allows for reducing batch sizes without increasing production costs. Topics include:
a. Understanding what Setup is and the 5 step approach.
b. Why Setup Reduction is necessary for Lean.
c. How to implement on individual setups.
d. How to implement and sustain throughout the plant.
Module 10: Total Productive Maintenance (TPM) and the Shop Floor
Day 5: Afternoon Session
TPM is an equipment operating philosophy that aims at extreme productivity by relying on team-based activities to completely eliminate equipment breakdowns, defects, and other manufacturing losses. The SME video, Total Productive Maintenance, is included as part of this module. Participants will learn how to ensure high equipment reliability, maintainability and performance. Topics include:
a. Bringing equipment to optimal condition to ensure a high level of availability.
b. Developing a maintenance program for the life of the equipment.
c. Ensuring continuous improvement.
d. Training operators and maintenance personnel for TPM.
e. Involving all departments and all levels through support, participation and ownership.
f. Implement objective measurement system (OEE) to identify action items and monitor progress.
g. Improvement examples from TPM projects.
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