In the Cost Accounting Training Course, you will learn the accounting process used for the recording, classifying, analyzing, summarizing, allocating, and evaluating all key costs, including inventory valuation, job costing, production process costing, standard costing, and fixed costs such overhead and depreciation of capital equipment, to enable management to consider various alternative courses of action and control of costs based on cost efficiency and company capability.
LEAN MANAGEMENT CERTIFICATION TRAINING COURSE
- Learn industry-recommended lean manufacturing procedures and best practices.
- Receive training from a lean professional with 30+ years of experience.
- Four ways to learn: public class, webinar, self-study, or on-site training.
- Public class and webinar limited to four students for maximum learning.
- Certificate issued on completion.
- Cost: Three-day class $1,999.00
- Available discounts
Learn lean manufacturing in-person or online in this three-day class.
Module One: Continuous Improvement Tools
Asian culture has had a significant impact on the rest of the world. Within the business environment, Japan has contributed greatly to the language of business with numerous concepts that represent continuous improvement tools (kaizen tools) and with production philosophies such as just-in-time. Just-in-time (JIT) philosophy is also known as lean manufacturing. In this first module, both of these production philosophies will be discussed.
Another important philosophy that will be studied in this course is the concept developed by a Japanese consultant named Kobayashi. This concept is based on 20 keys leading businesses on a course of continuous improvement (kaizen). These 20 keys also will be presented in this module.
Finally, in this introductory module, the production core elements will be presented to focus on improvement actions, and a resource rate to measure improvement results is also explained.
In this module, you will learn about continuous improvement, improvement philosophies and methodologies, Just-In-Time (JIT), and measuring and prioritizing the improvements.
Module Two: Material Flow and Facilities Layout
Several productivity metrics, such as throughput and lead time, are directly affected by where and how the processing and storage resources are located in a factory. In this module, you will learn about the different types of industrial processes and plant layouts.
Plant layout (changes in resource or even factory location) is an activity that all companies are forced to deal with sooner or later. These situations occur because of technology innovations, increases in demand, and certain other productivity reasons. Therefore, it is important to be familiar with the methodologies used to carry out these kinds of studies.
Cellular layouts, where labor and machines are grouped in cells, will be presented in this module because they are becoming increasingly important and also because they require specific methodologies. Cellular layouts will be explained in greater depth in Module Three.
In this module, you will learn about layout improvement and its theoretical basis, layout design methodology, and tools for layout study.
Module Three: Material Flow and the Design of Cellular Layouts
In Module Two, the concept of manufacturing cells was presented as a specific case of the product/process layout. The basic analysis necessary to transform a traditional factory into a cellular layout requires a unique development and implementation methodology. Because of this difference in layout analysis and philosophy, a separate module on cellular design and analysis is used for this important topic.
The use of cells creates a unique set of production modules. The plant’s division into cells exclusive to the production of a product family transforms the factory into a group of self-managed sub factories or modules. This module presents some design and analysis tools focused on getting a company ready to progress to cellular manufacturing.
When a production line is being designed, it is important to distribute the needed manufacturing tasks within the workstations as best as possible. One always should avoid any unneeded workstations so that task distribution can be well defined and developed and lead time can be reduced, along with work-in-process and labor costs. In this module, line-balancing techniques will be explained and developed.
In this module, you will learn about the assembly line and its theoretical basis, and cell design methodology.
Module Four: Equipment Efficiency: Quality and Poka-Yoke
Shigeo Shingo developed a system to improve inspection tasks to guarantee 100 percent quality for manufactured parts, leading toward a defects-free process. This module will explain inspection processes based on unnoticed mistake-proving devices (called poka-yoke). This type of inspection strategy complements statistical process control (SPC) and is used primarily for inspecting logical features.
Poka-yokes are visual and physical tools used in conjunction with source inspection (a concept also created by Shingo) for the two techniques to be effective. Source inspection also will be presented in this module.
In this module, you will learn about poka-yokes and their theoretical basis and poka-yoke design methodology.
Module Five: Equipment Efficiency: Performance and Motion Study
This module will examine the second equipment efficiency indicator based on two factors: equipment performance losses due to stoppages (usually not registered) and equipment performance reduction caused by equipment component deterioration or wear. In Module Seven, we will study equipment availability (setup reduction) and quality related to startup.
Small breakdowns or device (fixture and tooling) holdups are responsible for these machine stoppages. In other cases, an improper adjustment or interaction between the worker and the machine cycle also can create problems.
Time and motion study allows one to optimize the relationship between the worker and the machine, as well as to investigate whether the worker can tend more than one machine in those cases where the machine cycle is significantly longer than the worker cycle.
The main tools presented in this module are worker-machine and machine-machine diagrams. These tools help us study the relationship between worker and machine cycles (or between machines), eliminating or reducing idle time and optimizing the working cycle.
In this module, you will learn about motion study and its theoretical basis and motion study tools.
Module Six: Equipment Efficiency: Availability, Performance, and Maintenance
The role of maintenance is to ensure the proper functioning of all company hardware. Most maintenance departments are considered, by most companies, a necessary evil or a money pit that represents an ongoing cost. Managing a maintenance department can be nearly impossible because the investments required to improve production processes usually take on a low priority or, even worse, may not even make it to the priority list for capital expenditures.
Maintenance evolution and maintenance techniques evolution have been developed in parallel for many companies: The maintenance department’s first obligation is to remediate hardware failures that have occurred already. The next obligation after fixing breakdowns is to prevent future problems with the equipment that eventually may lead to failure.
The companies most advanced in maintenance management try to incorporate basic maintenance tasks into their daily production routine with direct labor personnel checking fluid levels and examining production equipment for potential failure mechanisms, also searching for ways to increase the ability to predict potential equipment breakdowns.
In this module, you will learn about equipment maintenance and its theoretical basis, maintenance program implementation, and maintenance tools.
Module Seven: Equipment Efficiency: Availability, Quality, and SMED
It has become increasingly important to manufacturing products economically in smaller and smaller batches. New management philosophies demand product lead times (both development and then manufacturing times) are kept as small as possible. Product customization has increased, increasing the number of parts in a product family. As a result, batch sizes have been reduced and continue to shrink.
In this context, companies should be as agile and flexible as possible. Part of the required agility is to reduce machine setup times to minutes instead of hours. Unless setup time can be reduced significantly, it will be difficult to produce small batches and reduce lead time economically.
The single-minute exchange of dies (SMED) methodology, as it is called, is a clear, easy-to-apply methodology that has produced good results in many cases very quickly and amazing results in some other cases. Shigeo Shingo developed the SMED methodology in Japan from 1950 to the 1980s. With this methodology, it is possible to achieve good results without costly investments, which makes implementation in many factories an easy decision to make,
In this module, you will learn the setup process and its theoretical basis, SMED methodology, SMED tools, and SMED effects and benefits.
Module Eight: Environmental Improvements and the 5S Methodology
The third area analyzed in this course is the work environment and how it can be improved. The number of implementation projects based on a methodology known as the 5S methodology has increased significantly in the last decade. This methodology’s name corresponds to the initial letters of five Japanese words (also five English words) based on sort, organize, and clean.
However, the main objective of the 5S tool is to educate workers and encourage an attitude that supports worker habits. These habits will allow workers to maintain the work environment in an orderly (sorted, organized, and clean) manner with little effort. The ideas used in this methodology are simple, and most of them are based on common sense. However, in most companies, these procedures of organization and cleaning are not adhered to as well as they should be.
In this module, you will learn about clean and organized workspaces, 5S implementation methodology, implementation of the 5S in offices, 5S tools, and 5S benefits and effects.
Module Nine: Other Improvement Keys
In previous modules, different improvement tools that can be used to solve many production problems were discussed, illustrated, and analyzed. These tools are included in the course 20 Keys to Workplace Improvement, but not all 20 keys have been explained. The rest of the keys can be grouped into four categories:
- Human resources
- Efficient materials use
- Visual control
In this module, you will learn about human resources-related keys, visual control-related keys, and technology-related keys.
In Maintenance Planning and Scheduling Training students will learn the administrative processes that cover all aspects of operations, from workforce activities to asset maintenance, repair, and overhaul that take place in a fleet MRO operation.
In Production Management Certification Training, you will learn how to apply management principles such as planning, organizing, directing, and controlling the production process to a factory’s production function.
In the Production Planning, Scheduling, and Control course students will learn the administrative processes that cover all aspects of operations, from workforce activities to product delivery, that take place in a manufacturing company.
In the Six Sigma (6σ) Certification Training Course, you will learn this management ideology that provides organizations with techniques and tools for process improvement to increase performance and decrease process variation to reduce defects and improve profits, employee morale, and quality products or services.
In the supply chain management (SCM) training class, working professionals will learn to optimize their supply chain operations through efficient design, planning, execution, control, and monitoring of supply chain activities with the objectives of creating net value, building a competitive infrastructure, leveraging logistics, synchronizing supply with demand, and measuring performance.
In the Warehouse and Inventory Management Certification Course, you will learn to efficiently control the day-to-day operations of this vital part of the supply chain process.