Lean Training Course Outline

Module 1 Continuous Improvement Tools

• Continuous Improvement
• Improvement Philosophies and Methodologies
  • Just-In-Time (JIT)
  • Thinking Revolution
  • Lean Manufacturing
• 20 Keys to Workplace Improvement
• Measuring and Prioritizing the Improvements

Module 2 Material Flow and Facilities Layout

• Layout Improvement
  • Signs and Reasons for a Need to Change the Layout
• Theoretical Basis
  • One-Piece Flow
  • Main Types of Industrial Companies
  • Layout Types
  • Characteristic of the Traditional Layouts
• Layout Design Methodology
  • Step 1 Formulate the Problem
  • Step 2 Analysis of the Problem
  • Step 3 Search for Alternatives
  • Step 4 Choose the Right Solution
  • Step 5 Specification of the Solution
  • Step 6 Design Cycle
• Tools for Layout Study
  • Muther’s 8 Factors

Module 3 Material Flow and Design Of Cellular Layouts

• The Assembly Line
• Theoretical Basis
  • Mass Production
  • Flow or Assembly Lines
  • Cell Layout Design Justification
  • Basic Cells Design Nomenclature
• Cell Design Methodology
• Cell Design Tools
  • Line Balancing
  • Group Technology
  • Time Study
  • Leveling Production
  • Multifunctional Workers
  • Workforce Optimization

Module 4 Equipment Efficiency: Quality and Poka-Yoke

• Poka-Yokes
• Theoretical Basis
  • Inspection and SQC (Statistical Quality Control)
  • From SQC To Zero Defects
• Poka-Yoke Design Methodology

Module 5 Equipment Efficiency: Performance and Motion Study

• Motion Study
• Theoretical Basis
  • Motion Economy Principles
• Motion Study Tools
  • Value Analysis
  • 5W2H and 5-Why Methods
  • Worker-Machine Diagram
  • Machine-Worker Ratio
  • Machine-Machine Diagram

Module 6 Equipment Efficiency: Availability, Performance, and Maintenance

• Equipment Maintenance
• Theoretical Basis
  • Types of Maintenance
• Maintenance Program Implementation
  • Getting Started
  • Corrective Maintenance Implementation
  • Preventive Maintenance Implementation
  • Autonomous Maintenance
  • TPM – Total Productive Maintenance
  • RCM – Reliability Centered Maintenance
• Maintenance Tools
  • FMEA for Equipment
  • Reliability
  • PM Analysis
  • Maintenance Management

Module 7 Equipment Efficiency: Availability, Quality, and SMED

• Setup Process
• Theoretical Basis
  • Basic Steps in a Setup Process
  • Traditional Strategies to Improve the Setup Process
• SMED Methodology
  • Preliminary Stage
  • Stage 1 Separating Internal and External Set-Up
  • Stage 2 Converting Internal Set-Up to External Set-Up
  • Stage 3 Streamlining All Aspects of the Setup Process
• SMED Tools
  • First Stage Tools
  • Second Stage Tools
  • Third Stage Tools
  • Zero Changeover
• SMED Effects and Benefits
  • Easier Set-Up Process
  • On-Hand Stock Production
  • Workplace Tasks Simplification
  • Productivity and Flexibility
  • Economic Benefits

Module 8 Environment Improvements and the 5S

• A Clean and Organized Workspace
• 5S Implementation Methodology
  • Getting Started
  • Common Steps in the Five Pillars
  • First Pillar: Sort
  • Second Pillar: Set in Order
  • Third Pillar: Shine
  • Fourth Pillar: Standardize
  • Fifth Pillar: Sustain
• Implementation of the 5S in Offices
  • Applying 5S to Computers
• 5S Tools
  • Red-Tagging Strategy
  • Sign Strategy
  • Painting Strategy
  • Preventive Order
  • Preventive Shine
  • Promotion Tools
• 5S Benefits and Effects

Module 9 Other Improvement Keys

• Human Resources Related Keys
  • Rationalizing the System
  • Improvement Team Activities
  • Empowering Workers to Make Improvements
• Efficient Materials Use Related Keys
• Developing Your Suppliers
• Conserving Energy and Materials
• Reducing Inventory
• Visual Control-Related Keys
  • Andon
  • Kanban
• Technology Related Keys
  • Jidoka
  • Using Information Systems
  • Leading Technology and Site Technology