Training Course Program
Lean Manufacturing - 3-day course
how to increase drastically quality, productivity and "responsiveness" in the Manufacturing Industry
course contents and main topics
World Class Manufacturing Operations - understanding the scenario (more »)
Productive Systems - The "batch" and "line" types of Operations - The "push" and "pull" productive methods (more ») - The kanban approach to pull production (more »)
Value Adding Management in the manufacturing industry - Focusing on the productive processes to maximise the output value (more »)
Productive Process Time and Cost Analysis : identifying value-adding and non-value-adding activities (more ») - Case study: "spot the waste !"
Understanding "takt-time", "throughput-time", WIP (work-in-progress) and their inter-relationships
The target : Flow Production, or production with no waste (more »)
The relationship between JIT-Just in Time, LM-Lean Manufacturing and Flow Production (more »)
The small-lot production systems: the smaller the lot, the less the waste ! - Simulation: One-Piece Flow - Case study: One-Piece Flow vs. Batch Production
Systematic Elimination of Waste in the manufacturing industry (more ») - What is waste : classification of waste - The SOCO (5S) approach as a starting point for fighting waste (more ») - Halting waste proliferation - Reducing waste - Eliminating waste
Flow Production in three different situations: labour-intensive - machine-intensive - combination. Case studies
The stock issue: why does stock pile up and (sometimes) flood the factory?
What are the necessary requirements to implement Flow Production - Flow Production golden rules (more »). How to reduce drastically all lead times through Flow Production: produce today what your customers ordered yesterday
Is Continuous Flow Production suited to you ? The Product-Quantity Analysis - Process Mapping - Process-Razing studies
Cell Production and Group Technology - Design of manufacturing cells : principles and techniques. When to consider One-Piece production and Cell Manufacturing. How to improve productivity by an average of 35%, by eliminating the bulk of the waste (more »).
Flow Production and Quick Change-Over : the missing link (more »). How to improve set-up and change-over time by 50% to 80%. How to achieve "instantaneous change-over" situations. Live simulation.
Plant, Equipment, Machinery, Layouts and Flow Production - The relationship between Lean Manufacturing and TPM, Total Productive Maintenance (more »). TPM basic principles for the Manufacturing Industry. Not all machines are suited for Flow Production: how to avoid the "super star galactica" cul-de-sac.
TQM-Total Quality Management (more ») and Lean Manufacturing - Flow Production to maximise quality and productivity - the link quality/productivity. The 100% testing approach in Manufacturing: case study. Lean Disciplines: the Poka-Yoke (more ») approach for zero-defects - interactive case study. Lean Disciplines: the 6 Sigma Methodology for drastic reduction of process' variability - overview.
How to deploy LM techniques in the manufacturing industry - starting from the top or from the bottom? Can Flow Production be extended factory-wide? The mixed "push/pull" compromise. Where and how to position the "coupling" between the "push/batch" and the "pull/flow" systems. Basic Lean and Continuous Flow principles for the Continuous Process manufacturing industry and the highly mechanised/automated factory.
Value Stream Management: a global approach to Lean (more »). The Value Stream Mapping technique: a practical deployment of all Lean Disciplines in an integrated fashion. The VSM "storyboard": a common, practical tool understandable both to Top Management and to Shop-floor people. The "Milestone Charter" and the Kaizen approach to the implementation of Lean Improvement projects.
New relationship with suppliers for Lean Manufacturing. Suppliers classification, rating and grading. Understanding the "Value-Chain" principle in manufacturing and the strategic role of suppliers and sub-contractors. Lean approaches to Supply Chain management. Is "co-makership" suited to you?
Operations Management for Lean Manufacturing - simple is beautiful! small is beautiful!
People for Lean Manufacturing: multi-skill, multi-function, flexible, responsible, empowered. New challenges for Human Resources Management, and new frontiers in people performance. Management's and employees' approach to Lean Manufacturing - TEI-Total Employee Involvement and Lean Manufacturing: the perfect symbiosis (more »)
Lean Manufacturing : a cultural revolution
Duration: 24 hours (typical)
The Lean Philosophy is changing the way organisations operate. No longer stuck in the paradigm of "mass" thinking, many manufacturing enterprises have tried to adopt some portions of the Toyota Production System, the Lean road. Many have failed. Many have rushed off, taken a course and pronounced themselves LEAN. Yet very few have tested the depths of overall performance enhancement and added competitiveness possible with a complete change of paradigms in the "lean" direction.
Research by Gallup has uncovered that less than 30% of employees are truly engaged in their jobs. Lean Thinkers have long shown that an additional 25-40% of the work done by most organisations is waste or non-value added. This means that 40% of every payroll dollar is easily lost.
My personal investigations have come to the conclusion that the manufacturing sector is polluted by an astonishing 35% of completely wasted labour. Can that be afforded any longer?
This course will be a shocking course for many of you. Because it demystifies all traditional principles of the first industrial revolution on which the majority of manufacturing enterprises, still today, are built or around which they operate. By presenting in rather great detail the philosophy of the second industrial revolution and the main tools and disciplines readily available to all manufacturing enterprises to perform in an "excellent" status, this course is a door-opener to lean practices for whoever is: ready to listen to the message - prepared to abandon obsolete principles, formulas and approaches - willing to get to "lean" status.
This course will prove that competitiveness today can no longer be achieved by merely cutting costs or revamping technology: because cutting costs has a floor, while performance improvement through maximisation of value-added and waste elimination has no ceiling -and because technology alone does not generate the levels of output value enterprises and organisations need to tackle the challenges of the new millennium.
I hope to see you there, best regards
In today's "global market", featuring vanishing borders and hot competition, manufacturers should adopt an integrated approach to modern ways of competing and performing.
This course is designed to give participants a practical, "hands-on" presentation of the Lean Manufacturing discipline, addressed to dramatic improvements in productivity, quality and reactivity to clients' needs and expectations (World Class Performance status).
Specific objectives of this course are:
- To highlight the vital importance of a global attention to "value" in the manufacturing industry.
- To make participants aware of the Value Adding Management and Systematic Elimination of Waste principles, and furnish hints and practical guidelines for their practical implementation in the manufacturing industry.
- To make participants acquainted with Lean Manufacturing, Flow Production and Cell Manufacturing principles, by studying practical cases of successful implementation
- To give participants practical criteria to identify, in their own manufacturing concern, those processes in which Lean Manufacturing techniques could be implemented smoothly
- To show the relationship between Lean Manufacturing and allied disciplines such as Total Quality Management, Total Productive Maintenance, Achieving Quick Change-Over, 6 Sigma, Value Stream Management and Total Employee Involvement
This course is very interactive and supplemented with abundant practical exercises and case studies
"a very thorough and comprehensive programme on all aspects of lean manufacturing"
General Managers - Operations Managers - Production Managers, Planners, and Supervisors -
Quality Managers and Plant Managers from manufacturing enterprises.
You are welcome to request further clarifications about this course - please be as specific as possible. Just contact Carlo Scodanibbio
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