Lean Manufacturing Expert

This 12-Day modular programme is designed to train delegates in the full range of Lean Manufacturing tools. Successful candidates will be expected to champion the implementation of Lean Manufacturing within their organisation and cascade Lean thinking & action across the entire organisation. Understanding of the essential tools and techniques is reinforced through the use of case studies, examples and exercises.

Project work commences in parallel with the training, with delegates undertaking live projects throughout the duration of the programme. Regular project reviews are held as part of the training programme to ensure the vital link between theory and practice.

Course Content

Introduction to Lean Manufacturing
- Lean manufacturing and customer focus
- Lean vs traditional approaches
- What can be achieved?
- Examples and case studies
- Waste Elimination
- Value adding activity vs waste
- Sources of waste in manufacturing

5S Workplace Organisation
- How to achieve an organised workplace
- The 5 S's: Sort, Straighten, Sweep, System, Sustain

Visual Management
- Shared information and participation
- Different types of visual management

Plan Do Check Action Problem Solving
- Structured approaches to problem solving
- Problem solving vs fire fighting
- Establishing the Team
- Data collection – what data to collect
- Define and Quantify the Problem using SMART objectives
- Determine and Verify Root Causes
- Implementation and Verifying Solutions: Pilot testing and validation

Lean Measurements
- What is an SOP
- How to construct and use them
- Constructing a KPI cascade
- Identifying Lean Metrics

Risk Recognition
- The need for Process FMEA
- Linking important process steps to product characteristics to identify potential failures
- Setting priorities
- Cause analysis and countermeasures
- Evaluating the effectiveness of controls
- Risk Priority Number and Corrective Actions

Mistake Proofing
- Types and sources of errors & defects
- Types of inspection systems
- Identifying mistake proofing opportunities
- Mistake proofing in manufacture
- Examples and case studies

Process Mapping
- Types of process map
- How and when to use each
- Benefits and action planning
- Examples and case studies

Value Stream Mapping
- Mapping current state material and information flow
- TAKT time calculation
- Overall Equipment Effectiveness (OEE)
- Value stream time calculations
- Developing the future state map & Cell Design
- Focusing continuous improvement

Project Reviews

Interpersonal Change Management
- Coaching others for change
- Effective Team Working
- Facilitation Skills
- Conflict & time resource
- Site Central practical exercise

Rapid Changeover (SMED)
- Changeover definition & changeover activities
- Classification of changeover activities
- Continuous improvement and Rapid Changeovers
- Examples and case studies
- Team Based Exercise

Concurrent Engineering
- How Concurrent Engineering is used
- "Voice of the Customer" and translation
- Where should cost go in the product & process?
- Creativity and optimisation
- Categorising manufacturing difficulties

The Lean Office
- Lean thinking in the Office
- Identifying categories waste in administrative processes
- Building a sustainable continuous improvement culture
- Visual Management techniques
- Examples of good practice

Push vs Pull Logistics
- Kanban techniques for controlling movements and production
- Various types of Kanban system
- Calculating quantities
- Practical Exercise

Lean Supply Chains
- How Objectives of supply chain management
- Supply chain dynamics – the 'bullwhip effect'
- Supplier selection and relationships
- Benefits of supplier partnerships
- Techniques to support supplier development

Final Project Reviews

Lean Culture & Organisation Resources
- Programme review
- Presentation of certificates