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LDM 020 – Lean Management

LDM 020 – Lean Management

Teachers
Mr Mohan Selvaraju
Category:
In-House Programs / Leadership / Management / Softskills /
LDM 020 - Lean Management

Duration: 2 Days
Lectures: InHouse
Certificate of Completion

Introduction

Lean thinking begins with driving out waste so that all work adds value and serves the customer’s needs. Identifying value-added and non-value-added steps in every process is the beginning of the journey toward lean operations. In order for lean principles to take root, leaders must first work to create an organizational culture that is receptive to lean thinking. The commitment to lean must start at the very top of the organization, and all staff should be involved in helping to redesign processes to improve flow and reduce waste.

In today’s business environment, where global competition and constant price reduction demands from customers impact heavily on management decisions, Lean Enterprise concepts have helped companies to remain competitive, innovative, and profitable. “Lean” implementation results in enhanced cost and cycle-time reduction, customer satisfaction, and standardized high quality. This two-day course will focus on lean methods that can be used to minimize all forms of waste and maximize value for the customer.

Objectives

At the end of this training session, among others, participants will be able to:

  • Understand the difference between traditional “push” and the lean “pull” systems.
  • Identify typical wastes of lean and how those wastes reduce an organization’s profits, competitive edge, and customer satisfaction.
  • Recognize how lean directly addresses the elimination/reduction of operating costs, cycle time, and non-value-added activities.
  • Make better use of employees’ time and brainpower in a team environment.
  • Developing a plan for starting a lean journey in your organization.

Methodology

  • Interactive lectures
  • Group Discussions
  • Examination of case studies
  • Practical exercises

2 Days Training Modules

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Day 1

  • From a practical perspective.
  • Toyota Production System and Lean.

  • Identifying the eight waste.
  • Explain value-adding versus non-value adding.
  • Define value from the customer’s perspective.
  • Briefly describe how each of the seven wastes detracts value from a process.

  • Define the bounds of a workflow
  • Use a variety of process (workflow) mapping techniques
  • Identify hand-offs, disconnects, incomplete communication and network as non-value adding components (or waste)
  • Plan improvements to work
  • Consider a move from batch processing to continuous flow

  • Knowing Time Management.
  • Identify process bottlenecks.
  • Calculate Process Cycle Efficiency.
  • Understand how to balance workloads within a process workflow.

Day 2

  • Identify each of the 5S’s.
  • Know how to clear clutter from a work area.
  • Explain the rationale for selecting effective designated storage locations.
  • Understand how to maintain the work area’s clean.
  • Describe what it means to standardize and why standardization is important.
  • Know how to use audits to sustain workplace organization and to prevent backsliding.

  • Understand the error-proofing mindset.
  • Be aware of common error-proofing techniques.
  • Comprehend the Transaction Model.
  • Know how to use basic root cause analysis tools.

  • Measure Lean efforts by tracking Process Cycle Efficiency trends
  • Create a Balance Scorecard to track waste reduction
  • Audit 5S activities to maintain workplace organization momentum
  • Monitor uptime, throughput rates and yields using Overall Equipment Effectiveness

  • Organizational Level Process Map.
  • Process Analysis.
  • Pareto Chart.
  • Workload Balancing & Demand Leveling.
  • Standard Level.
  • Poka Yoke (Mistake Proofing).

About Instructors

Mr Mohan Selvaraju
- Council Member of the Charter Institute of Logistics & Transport - Warehouse Management and Operations - Material and Supply Chain Management