Lean Manufacturing

Learn how to use the power of "lean". Our program begins with a day-long lean manufacturing simulation that introduces the major concepts.

Following the simulation is an implementation program that includes a step by step approach of how to implement "lean" in the workplace. Topics include: Process Mapping, Standardization, 5S Visual Management, Teams, Job Instruction, Problem-Solving Tools and Kaizen.

Program Format: Eight hours of simulation followed by 120-140 hours of implementation training (actual hours will fluctuate with each organization).

Maximizing Efficiency with LEAN Manufacturing

1 Day Seminar

This is not just for manufacturers – it’s for any organization striving to dramatically increase production and simultaneously slash costs. This training offers a powerful, hands – on simulation, which demonstrates the effectiveness of continuous improvement of work methods to maximize efficiency.

During this energizing day of training you will work on a simulated production floor producing an actual product. You will see, feel and measure the effects as different LEAN Manufacturing principles are incorporated into the production process. These principles include concepts such as built – in quality, visual control, just in time, pull system, work leveling, continuous improvement, and teamwork.

After completing this training simulation you will be able to:

	Differentiate between a push and pull system
	List the wastes which must be eliminated to make a process lean
	Explain how waste reduces your company’s profits
	Explain the Kaizen process
	Understand how a kanban works
	Make more effective use of employee time.

Visual Control Systems

Your plant must be able to respond quickly to the needs of the market place with constantly changing workflow and production goals and zero defects. The key to this world class flexibility and high quality is the ability to understand at a glance what is going on in the workplace.

This visual program dealing with control systems will help participants become involved in monitoring the manufacturing process in a variety of ways. Participants will learn how to plan and promote a visual control system factory –wide, how to implement the system throughout, and how to incorporate it into a 5S program, while improving the system over time.

Mistake-Proofing

The Z Q C Approach

This program is intended to provide knowledge that can be used to make the workplace more productive and jobs simpler and more satisfying. It’s about a way to manufacture or assemble products that have zero defects by catching or fixing human mistakes and machine errors before they can cause defects.

The mistake-proofing approach that participants will learn in this program means establishing a quality control that ensures zero defects, not just a reduction in defects. This Z Q C focuses on correcting the conditions for processing, not on blaming people for making mistakes.

Quick Changeover:

The SMED System

This program focuses on how to do equipment or product changeovers in record time, often under 10 minutes. The method is called SMED, which means “Single Minute Exchange of Die”.

The SMED approach is simple and universal. It works in companies all over the world. It’s about thinking about change over in a new way. It can make the workplace more productive, reducing difficult, time-consuming and wasteful activities in your organization; which should result in a more competitive position and easier work.

Just In Time For Operators

Just-in–time manufacturing is an approach that can dramatically boost your company’s competitiveness by eliminating waste from the production process. The change from traditional large –lot production to just-in-time requires a new understanding about what adds value to the customer and what does not. Although management determines the manufacturing approach, front line operators and assembly people play a key role in making it happen.

This program is intended to share basic knowledge with participants that will help them participate effectively in this change.

Cellular Manufacturing

One-Piece Flow for Workteams

The change from traditional large-lot production to lean manufacturing requires a new understanding about what activities add value for the customer.

Cellular Manufacturing is an aspect of lean production that can dramatically boost a company’s competitiveness by eliminating waste from the manufacturing process. By arranging people and equipment into efficient, process-based cells, cellular manufacturing creates a smooth flow that shortens the lead time for delivery to customers. It also supports low inventory production of a variety of products to meet customers needs.

This program will asset companies as they implement cellular manufacturing and other lean production approaches.

The Visual Factory

Can you imagine playing a game where no one knows the score? How long would it take before you lose interest in the game? Knowing the score makes the action interesting by defining what it means to win and whether the team has a chance to win.

The situation in the workplace is really the same. People want to know how they are doing; What’s the score? This program focuses on ways to effectively communicate to employees, keeping them informed about their efforts and the impact on overall team and organizational goals.

Visual communication is a proven way to make information available and understandable to all who view it. This program reviews ways to make this communication effective.

5 S for Operators

This program is intended to give participants, powerful knowledge that can be used to make the workplace cleaner and safer and jobs simpler and more satisfying. It’s about how to create a workplace that is clearly organized, free of clutter, arranged so that things are easy to find and sparkling clean. What participants will learn is often called the “5S Method” which refers to the basic elements of the system: “Sort, Set in order, Shine, Standardize, and Sustain”. These activities provide a basic foundation for an effective workplace.