Lean Manufacturing Essentials

Massive benefits can be gained by concerted and systematic efforts to eliminate waste, improve process performance, speed up product flow and change unproductive practices. This exclusive fast-track Lean EssentialsTM programme provides a structured approach to Lean Manufacturing, and focuses on the key tools and techniques needed by improvement project leaders.
Practical exercises and case studies are used throughout the programme to reinforce the learning, and companies can use the powerful Lean EssentialsTM approach to create an improvement 'taskforce' – skilled to develop the business to even higher levels of performance.
The Lean EssentialsTM programme is also available on an in-company basis, and can be tailored to suit specific needs, incorporating shop floor improvement activities as appropriate. Additionally, a certificated 'Lean Facilitator' package is available to delegates wishing to undertake a lean improvement project with guidance from an experienced Smallpeice coach.

Course Content

Day 1

Lean Manufacturing & Waste Elimination
•Intro to Lean
•Waste elimination
•Performance measurement
•Continuous improvement (Kaizen)

5S Workplace Organisation & Visual Management
•Sort, straighten, sweep, system, sustain
•Creating a visual workplace
•Standard operating procedures

Day 2

Structured Problem Solving
•Developing a structured approach
•Identifying & prioritising improvement projects
•Team formation & action planning
•Data collection
•Analysing the facts & establishing root causes
•Creative solution generation
•Pilot testing & validation
•Formal adoption of solutions
•Performance review

Day 3

Optimising OEE & TPM
•Total Productive Maintenance (TPM)
•Measuring & improving Overall Equipment Effectiveness (OEE)
•Autonomous Maintenance

Effective Team Working
•The dynamics & process of change
•Building commitment to change
•Leading, building & coaching improvement teams

Mistake Proofing (Poka Yoke)
•Objectives of mistake proofing
•Errors & defects
•Systems for achieving zero defects
•Mistake proofing in manufacture, design & the office

Day 4

Rapid Changeover Techniques (SMED)
•Rapid changeovers & competitive advantage
•Terminology & targets
•Changeover analysis
•Changeover reduction exercise

Value Stream Mapping
•Benefits of mapping the value stream
•Current state mapping
•Identifying improvement opportunities

Day 5

Making Products Flow
•'Just in Time' principles
•Pull vs. Push systems
•One-piece flow & Kanban systems
•Layout considerations
•Cellular manufacturing
•Standard operations & balancing to TAKT time
•Future state mapping & implementation

Factory Simulation