OPS 001- Lean Manufacturing Practices

OPS 001- Lean Manufacturing Practices

Teachers
Yim Sze Khuen
Category:
In-House Programs/ Logistic & Quality/ Operation/Process/
lean manufacturing practices

Duration: 2 Days
Lectures: In House
Certificate of Completion

Introduction

Lean is a philosophy and set of management techniques focused on continuous “eliminating waste” so that every process, task or work action is made “value adding” (the real output customer pays for!!) as viewed from customer perspective. Lean “waste elimination” targets the “Eight Wastes” .

Through a mixture of presentations and discussions including group and individual exercises, this 2 day intensive training course will provide a systematic approach for Lean Management implementation practices applicable for both the manufacturing and maintenance environment. The student will be provided with a toolbox of techniques for problem solving, continuous improvement, plus practical advice ranging from operating a Lean facility on a day-to-day basis to understanding how to sustain the Lean program.

Objective

Key learning objectives include:

  • Develop a Lean Program for Their Facility
  • Measure Performance in Order to Achieve Desired Outcome
  • Create Value Stream Mapping
  • Enhance the Responsiveness and Effectiveness of Material Flows
  • Forecast Demands Accurately to Improve Scheduling
  • Manage Your Workforce Effectively for Continuous Improvement
  • Implement Rapid Process Improvements
  • Identify Wastes and How to Eliminate Them
  • Understand What in Needed to Sustain the Gains

Who Should Attend?

  • Human resources manager, leader, supervisor of management or an organizationThe course is designed for anyone who is concerned with continuous improvement, maintenance, manufacturing and process excellence as well as technical professionals seeking cutting-edge tools, proven approaches and real-world applications. This seminar is a must for anyone who is involved in maintenance or manufacturing at industrial plants, utilities or commercial facilities, including:
    • Operations Managers
    • Plant Managers
    • Maintenance Managers
    • Engineering Technicians/ supervisors
    • Quality Managers / Executives/ Supervisors
    • Materials Managers/ Executives / Supervisors
    • Manufacturing Engineers / Supervisors

    *     Production Managers/Executives/Supervisors

Training Content

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Day One

  • Familiarize Participants with Lean concepts so they are able to:
    • Identify the basic principles and objectives of Lean.
    • Define how continuous improvement is an ongoing activity and must be
      constantly reinforced.
    • Define how change must be sponsored by management and move down
      through the organization.
    • Recognize how Lean tools and techniques help eliminate waste from
      processes.

     

  • An overview of learning to see the flow of customer value from the product or service perspective and be able to:
    • Identify and collect accurate data to design Current State Maps.
    • Apply Lean icons to develop Value Stream Maps.
    • Create a current state Value Stream Map
    • Identify areas of improvement to perform Kaizen events.
    • Calculate takt time through a classroom exercise.
    • Create a future state Value Stream Map.

  • Enhance the organization of your workplace through the application of proven tools and be able to:
    • Recognize differences in appearance and functionality before and after a
      5S implementation.
    • Explain the potential benefits by implementing the concepts of Sort, Set
      in Order and Shine.
    • Applications of basic Standard Work procedures that will help maintain
      and control an organized workplace using visual controls.
    • Explain methods to Sustain workplace organization.
    • Describe how 5S can help to improve workplace environmental health
      and safety.

  • Understand and implement the Poka-Yoke methodology
  • Understand and practically employ the basic techniques associated with
    Zero Quality Control (ZQC) and Poka-Yoke.
  • Identify where ZQC and Poka-Yoke can be used for best effect
  • Coordinate and motive the Poka-Yoke team to provide real, tangible
    solutions to what appear to be intractable quality problems.
  • Train others in the ZQC and Poka-Yoke methodology

  • Benefits of Standardized Work
  • Use standardized work basic concepts and examples from various
    industries.
  • Observe work before you standardize it.
  • Use the elements of standardized work (takt time, work sequence,
    standard in-process inventory).
  • Identify the documents for establishing standardized work (production
    capacity sheet, combination table, work chart).
  • Define the requirements for standardized work (work, equipment and line,
    quality)
  • Standardize: poka-yoke, visual systems, checking and auditing.
  • Choose the standardization techniques suitable for your environment so
    that you can effectively ensure your process is consistent and your results are predictable.

  • Participants will be tested with quizzes regarding the input of the program on the 1st day
  • Prizes are provided to the top 3 participants who answer correctly

Day Two

  • What is Kanban? – Definitions
  • Understanding the origins of Kanban
  • Comparison of Push vs. Pull Systems
  • Kanban Card Types (Withdrawal, Conveyance & Production)
  • Types of Kanban systems (One card and Dual Card)
  • Kanban System Characteristics
  • Strengths and Weaknesses of Kanban
  • Planning for change
  • How to implement Kanban?
  • How Kanban can interface with MRP/ERP systems?

  • Definition and benefits for U shaped cell design
  • Use of multi-skilled, multi-machine operators and small flexible machines
  • Use of Jidoka (Automation) to eliminate machine watching Elements of a cell design
  • Process based layout
  • Standardized Work, 5S and Visual Management to support cellular
    manufacturing
  • Autonomous cell maintenance activities
  • Cell activity boards and measures

  • Define and measure setup.
  • Define the four stages of SMED.
  • Identify Internal and External setup.
  • Apply techniques to convert internal setup to external setup
  • Identify inexpensive techniques to reduce internal setup time
  • Describe how SMED relates to Lean Manufacturing, especially small lot
    production.

Enhance plant and equipment reliability to increase productivity and be able to:

  • Identify the basic components of total productive maintenance.
  • Describe the bath tub curve and machinery life cycles
  • Identify the Six Big losses in machinery
  • Design and implement autonomous maintenance plans
  • Train other operators in TPM activities
  • Assess the TPM needs of specific equipment to help achieve zero defects
  • Recognize faults and how to address them
  • Create a sample productive maintenance program for their plant.

  • Participants will be tested with quizzes regarding the input of the program on the 2nd day
  • Prizes are provided to the top 3 participants who answer correctly

About Instructors

Yim Sze Khuen
- Quality Management - Six Sigma Methodology - Soft Skills training