MPCEE
Lean Manufacturing FOUNDATION
COURSE
COURSE
NAME: LMFS
The objective of the LMFS TRAINING PROGRAMME is to coach
participants in the fundamentals of Lean Manufacturing, based on the different
aspects of the Toyota Production System - TPS, in order to streamline their
businesses and increase their profits
The five-day training programme, based on TPS, has been
devised specifically as a Foundation Course. Participants will have the
opportunity to obtain the optimum understanding of the different elements that
make up Lean Manufacturing. This will enable their businesses to become more
cost effective, economical and much more profit orientated in today’s
competitive marketplace.
The training programme opens and develops in such a way to
bring the participants together and put them at ease with the trainer and, of
course, the other way round to form a relaxed and informal climate.
Time
scales are flexible, dependent on the number of participants per training
programme.
DAY ONE
Duration Content
and Description
1h15 Introduction and Overview
(setting the scene)
1. Who am I?
2. What do I do?
3. Why LMFS?
(i)
To give participants the
information and understanding as a grounding to the identification and
assessment of the different aspects that make up Lean Manufacturing
(ii)
To offer fundamental and balanced
information, against the background of the world economy and the necessity to
install change, with the ability to reduce waste in all it forms
(iii)
To allow participants to return to
their businesses, in the knowledge that they will have the relevant information
on change management, to commence the processes of streamlining and increasing
the profits of their respective businesses
4. Obtain an inventory of their knowledge and experience of manufacturing
and specifically what their understanding of Lean Manufacturing is
5. Why Lean Manufacturing?
6. Radical change or go out of business - The Choice!
MODULE
0 LEAN MANUFACTURING BASICS
Lean Manufacturing Practices
An explanation of the disciplines that comprise the world wide
known
Lean practice is a coordinated
response to today’s highly competitive environment. Its roots lie in
manufacturing and are strongly influenced by the production system principles
originally developed at
Converting to Lean
practices is through the application and discipline to the fundamentals of the Toyota
Production System, which have achieved 50-70%
improvements in productivity, floor space, working capital, quality and safety
in a 2-4 year period.
Duration Content
and Description
2h00 MODULE 1 TPM
The important step in Lean Manufacturing implementation
Total
Productive Maintenance starts by creating a very much-needed bonding and
cooperation between maintenance crews and production operators, supervisors and
management. These forces have been traditionally antagonistic: production
blames on maintenance for any breakdown, production blames on the operators for
abusing the machine.
TPM is a discipline comprised of
most of the key ingredients of the Toyota Production System, now known as Lean
Manufacturing, such as:
·
Total participation
·
Employee empowerment
·
Leadership environment
·
Continuous improvement
·
Development of ownership feeling
·
Improved attitude and morale
·
Increased reliability
Once a good TPM program takes off, the benefits
start flowing to the whole organization. That is when many people start coming
on board. The participants feel encouraged and become familiar with
communicating their ideas, confident in the new listening attitude of the whole
team.
3H15 MODULE 2 5S’S
The Essentials to Lean Manufacturing Structure
Anyone who has recently opened a new machine shop
has certainly had these thoughts: How can I improve efficiency, work
organization, quality, safety and housekeeping and protect my investment at the
same time? The 5S process could effectively impact the way a company does
business.
Based on Japanese words that begin with ‘S’, the 5S Philosophy
focuses on effective work place organization and standardized work procedures.
5S simplifies your work environment, reduces waste and non-value activity while
improving quality efficiency and safety.
Day ONE WILL CLOSE OFF WITH HIGHLIGHTING THE
SALIENT POINTS AND ANSWERING QUESTIONS RELEVANT TO CLARIFYING CONTENT.
DAY
TWO
Duration Content
and Description
3H15 MODULE
3 JIT
Just in Time (a strategy for saving money)
Lean Manufacturing is about eliminating waste wherever it is. One
of the most important steps in the implementation of Lean Manufacturing is JIT.
Just in time is about not having anywhere in
the plant or outlet, more raw materials, sub-assemblies or products than the
minimum required for a fluent operation.
Storage is usually a hidden enemy of a healthy
operation. When raw materials, sub-assemblies or finished products stay
anywhere they represent a part of the capital of a company that is NOT
generating any profits. In addition to that loss of profit, it is at risk.
Floods, fires, market depreciation, and design obsolescence, are just some of
those risks. In some cases, raw materials used in products that have not moved,
could have been used to manufacture other products that would've sold faster.
3H15 MODULE 4 SMED
Single Minute Exchange of Dies
One
of the most important
improvements required in multiple industries, quick setup renders big profits. Once
taught, it is quite simple, just as all these disciplines are.
Although not frequent any more, changing a tire in our car
is a chore that will take anywhere between seven and fifteen minutes. Just try
to list the number of operations involved. Now, why is it that in the car races
they can change the four tires in just a few seconds? Here we should list the
differences:
·
They were prepared
·
Right
tools
·
Only
one bolt per tire
·
Continuous
training
·
Cumulative
experience, on and on...
Main
reason for them to put all those advantages together: They are in a fierce
competition! And so are all manufacturers today.
Day TWO WILL CLOSE OFF WITH HIGHLIGHTING THE
SALIENT POINTS AND ANSWERING QUESTIONS RELEVANT TO CLARIFYING CONTENT.
DAY THREE
Duration Content
and Description
3H15 MODULE
5 ZERO QUALITY CONTROL
Quality at the Source or Poka
Yoke
This
concept is the
right thing to do, as it is logical to do things right the first time. It is natural
to expect everyone to do his or her job right all the time. Therefore, why
inspect after staff have done their job? Does this send the wrong message?
Ostensibly, one is telling them that one does not trust their expertise or
their sense of responsibility.
3H15 MODULE 6 WORK
CELLS
Manufacturing
Cells vs Assembly Line
Cellular
manufacturing or a better use of space and other resources is perhaps one
of the most drastic changes some plants will ever experience. It is about
changing not only our psychological, but also the physical arrangement or
layout of the plant. Although it may seem quite complex, it is not. All these
changes will have to do with the new idea of Single Piece Flow, which is essential to a good
Lean Manufacturing environment. Work
cells are
such a good strategy because they encourage teamwork and cross training. The
communication among the cell members is easy and they are close to each other,
in order to prevent errors from passing through. The travelling distances of
people and products in process type manufacturing is the shortest possible. It
is much easier to balance the operation so that each operator gets a fair, even
workload. This will help implement a reliable process to comply with the Takt Time, which is the name given for a smooth operation to comply
with the market place.
Day THREE WILL CLOSE OFF WITH HIGHLIGHTING
THE SALIENT POINTS AND ANSWERING QUESTIONS RELEVANT TO CLARIFYING CONTENT.
pARTICIPANTS WILL BE ASKED TO RETURN IN THE MORNING
WITH DETAILS OF THE PROCESSES, IN THEIR BUSINESS, THAT THEY HAVE DIRECT CONTROL
OF. BE IT MANUFACTURING, ADMINISTRATION, STORES ETC.
DAY FOUR
Duration Content
and Description
3H15 MODULE
7 DESIGN FOR MANUFACTURE
Business Process Re-Engineering – BPR
The simpler the better and one of the big
changes in the automobile industry in the last few decades, for example, has
been the simplification in manufacturing. It has been reduced from tens of
thousands of parts to about 30% of that today. Look at cars made in the 50’s
and early 60’s, to those manufactured today to see this.
As in many of the products manufactured still
today, simplification is about to eliminate all the operations that do not add
any value to the product. It is amazing how a trained set of eyes can start
seeing simplification opportunities where they have been overlooked for years.
Methods can and have been devised to bring a workforce team to that level of
analysis and cooperation within a short space of time. They will start finding
the opportunities and motivation to improve the processes over and over again.
NB. Module 7 may run
into Module 8, due to the complexity of BPR.
3H15 MODULE
8 KANBAN
Simplified Visual Controls
Help
everyone become aware of what is going on, as we have been complicating
our processes and paperwork for material handling, work in process, and many
other aspects of our business.
Kanban is the lean manufacturing
approach to solve this problem. Kanban brings solutions through simple
devices like: cards, trays, containers, decals or different colour or image
coded devices. Kanban simplifies our lives.
By coordinating Kanban systems, they can make the flow of
your process much smoother. Kanban implementation is used as a
very useful tool and once you know it, many of its possible applications will
become apparent.
Day FOUR WILL CLOSE OFF WITH HIGHLIGHTING THE
SALIENT POINTS AND ANSWERING QUESTIONS RELEVANT TO CLARIFYING CONTENT
PARTICIPANTS
WILL BE ASKED TO SELECT AN AREA OR OPERATION OF THEIR PLANT TO BE IMPROVED.
THIS WILL BE USED IN MODULE 9 AS AN EXAMPLE OF A WORKSHOP.
DAY FIVE
Duration Content
and Description
3H15 MODULE
9 KAIZEN
Kaizen Events or Workshops
Kaizen Workshops or Kaizen Events are the bread and butter of the Lean Manufacturing World.
What
is a Kaizen Event?
It is
a very exciting process open to some eight to twenty of the most valuable
people in a company. The "team" is comprised of managers, operators,
maintenance technicians, and supervisors from all the areas of a company. They
all get together for a few days, usually 4 to 5 days is enough, and focus in
some particular area or operation of the plant to be improved.
Using
all the participants’ expertise, it is possible to organise these people to
share and discuss their ideas and experiences as well as their knowledge. By
assisting them, they can come up with simple, but very creative solutions
related to the subject and the techniques to take advantage of their
creativity.
3H15 MODULE
10 WASTES IN MANUFACTURING
These wastes are:
Defects
Waiting
Processing
Production
Motion
Inventory
Transportation
Underutilised Personnel Resources
On completion of the LMFS training
programme participants, drawing on their own knowledge and professional
experience and expertise, will be able to participate and give input as an
important member of their company’s business re-engineering programme. It will
also give participants the grounding to go on to other more specialised
training programmes available for Lean Manufacturing, available in a global
context.
Lean Manufacturing
Presentation
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