Lean Management: Lean Management in Manufacturing

• An interest in developing people, improving efficiency, and eliminating waste within the organization

Audience

• Business managers
• Quality assurance managers and consultants

Lean Management is an approach to running an organization. It promotes a long-term view of work and a culture of continuous improvement -- seeking to continuously and systematically achieve small, incremental changes in processes in order to improve efficiency and quality.

In this instructor-led, live training (onsite or remote), participants learn how to apply Lean principles and practices within a manufacturing context and establish a culture of continuous improvement.

The training combines case activities and discussions with live, hands-on practice using the tools, metrics, and methods needed to implement Lean systems and processes. Some of the concepts covered include:

• Determining the root cause of inefficiencies.
• Measuring performance.
• Realizing the continuous improvement cycle.
• Organizing Kaizen events.
• Instilling a mindset of Lean thinking across the organization.

Format of the Course

• Interactive lecture and discussion.
• Lots of exercises and practice.
• Hands-on implementation in a live-lab environment.

Course Customization Options

• To request a customized training for this course, please contact us to arrange.

Introduction

• History of Lean: The Toyota Production System

Lean Thinking

• Organizing human activities

Benefits of Lean

• Cash flow improvement
• Increased capacity for revenue

Five Principles of Lean

• Value
• The Value Stream
• Flow
• Pull
• Perfection

Types of Waste

• Seven types of waste
• Using the wrong metrics to measure waste

Measuring Performance

• Observing processes
• Understanding the key aspects of a KPI

Preparing the Enterprise for Lean

• Creating Lean processes
• Tracking work through Kanban
• Overcoming resistance to change

Implementing Lean in Your Organization

• Organizing the teams
• Kaizen and the continuous improvement cycle
• Developing people and partners
• Organizing the workspace for efficiency
  • 5 S+1: Sort, Straighten, Shine, Standardize, Sustain, Safety
• Reducing the time for equipment changeovers
  • SMED (Single-Minute Exchange of Dies)
• Calculating the pace of production (Takt time)
• Autonomation (Jidoka)
• Error proofing (Poka Yoke)

Value Stream Mapping

• Lean measurements
• Creating current and future state maps
• Just-in-time
• Built-in-quality

Promoting Lean Thinking across the Enterprise

• Tools + culture change
• Coaching
• Developing communication and feedback channels
• Focusing on long-term learning

Developing Lean Leaders

• Setting up a Lean leadership team
• Creating a succession system

Assessing the Results of Lean

• The Lean Maturity Matrix
• Tracking performance
• Benchmarking against other companies
• Continuous monitoring and improvement

Complementary Methodologies

• Agile and Scrum
• Six Sigma

Summary and Conclusion