Available for on-site presentation only at this time.
Lean is a powerful tool for improving operations. Its purpose is to help organizations service their customers in the fastest, most productive manner possible by eliminating non-value added activities. These non-value added activities are known as the seven wastes: extra motion, over production, unnecessary movement, waiting, inventory, rework and transport. Visual management techniques, Pull Systems, balanced work, cellular production, work teams and standardization are the tools that fight the Seven Wastes. These processes have been proven in hospitals, production facilities and distribution companies.
This workshop will provide an overview of these methods for associates who will be supervising, maintaining, planning, engineering or somehow supporting a Lean cell, department or facility. It teaches the four main tools of Lean Operations including:
- Value Stream Mapping
- 5S Visual Management
- Kanban Inventory Control
- Flow Velocity®
Throughout this workshop, these tools will be used to transform a batch operation into a Lean process. Each tool builds upon the previous one until a Lean process is achieved at completion.
- Increase speed within your company to serve customers faster
- Improve productivity through elimination of non-value added activities (waste)
- Reduce inventory
- Create a visual workplace where everyone knows what needs to be accomplished
The attendee will be able to:
- Learn how to value Stream Map, identify and quantify waste in your organization
- Utilize 5S Visual Management to improve productivity through organizing and standardizing your work place
- Create a Pull Systems using Kanban Control
- Streamline work processes using Flow Velocity® analysis and design
8:00 a.m. - 8:30 a.m.
A. Learning Objectives
B. Experiences Of Participants
8:30 a.m. - 8:45 a.m.
II. Benefits Of Lean Operations
8:45 a.m. - 9:00 a.m.
III. Where Does Lean Fit With Six
A. Speed And Accuracy
9:00 a.m. - 9:30 a.m.
IV. Interactive Simulation
A. Produce Trucks And Cars In A Batch Environment
B. Quantify Results
9:30 a.m. - 10:30 a.m.
V. Value Stream Mapping
A. Mapping Symbols, Terms And Technique
B. How To Map Material And Information Flow
C. Adding Cycle Time, Lead Time, Inventory And Other Metrics
D. Current And Future State Mapping
10:30 a.m. - 10:40 a.m.
10:40 a.m. - 11:00 a.m.
VI. Interactive Simulation
A. Create A Current State Map For The Truck And Car Production Process
11:00 a.m. - 12:00 p.m.
VII. 5S Visual Management
A. Sorting Frequently Used, Seldom Used And Unused Items In The Workplace
B. Creating A Place For Everything And Ensuring That Everything Is In Its Place
C. Red Tag Areas
D. Shadow Board Techniques
E. Set-In-Order In The Office
F. Visual Work Instructions – Standardizing Best Practices
G. 5S Auditing – Sustaining The Gains
12:00 p.m. - 1:00 p.m.
Lunch (On Your Own)
1:00 p.m. - 1:15 p.m.
VIII. Interactive Simulation
A. Implement 5S On The Truck And Car Production Line
1:15 p.m. - 1:30 p.m.
IX. Kanban Materials Management
A. Pull Systems
B. Kanban Calculation
C. Organization Of A Kanban System
1:30 p.m. - 1:45 p.m.
X. Interactive Simulation
A. Implement Kanban On The Truck And Car Production Line
1:45 p.m. - 1:55 p.m.
1:55 p.m. - 2:45 p.m.
XI. Flow Velocity® Processing
A. Breaking Up Work To Take Time
B. One-Piece Flow
C. Flexible Employees
D. Cellular Design
E. Kanban Control In Flow Velocity® Cells
2:45 p.m. - 3:30 p.m.
XII. Interactive Simulation
A. Design A One-Piece Flow Cell For Truck And Car Production
3:30 p.m. - 4:00 p.m.
XIII. Interactive Simulation
A. Run The One-Piece Flow Cell For Truck And Car Production
4:00 p.m. - 4:20 p.m.
XIV. Value Stream Mapping
A. Create The Future State Map Of The Truck And Car Production Process
B. Quantify Improvements
4:20 p.m. - 4:40 p.m.
XV. 5S Visual Management
A. Conduct A Visual Audit Of The Truck And Car Production Process
4:40 p.m. - 4:45 p.m.