Basics of Lean Manufacturing, TPM and Lean 6-Sigma

Description

INTRODUCTION

This course on Basics of Lean Manufacturing, TPM and Lean 6-Sigma is part of the Lean Manufacturing Tools Specialization series that is designed to give an introductory and intermediate level of familiarization on Lean manufacturing which is based on principles of the Toyota Production System (TPS).

Lean manufacturing is a systematic method for the elimination of waste within a manufacturing system. Working from the perspective of the client who consumes a product or service, “value” is any action or process that a customer would be willing to pay for. This management philosophy is derived mostly from the Toyota Production System (TPS). TPS is renowned for its focus on reduction of wastes to improve overall customer value.

Lean is a set of “tools” that assist in the identification and steady elimination of waste. A list of such tools include: SMED, value stream mapping, Five S, Kanban (pull systems), poka-yoke (error-proofing), total productive maintenance, redesigning working cells, pull processing, perfect first-time quality, waste minimization, continuous improvement, flexibility, building and maintaining a long term relationship with suppliers, autonomation, load levelling and production flow and visual control. TPS has two pillar concepts: Just-in-time (JIT) or “flow”, and “autonomation” (smart automation). The concepts of flexibility and change are principally required to allow production levelling (Heijunka), using tools like SMED.

Six Sigma is method of efficiently solving a problem. Using Six Sigma reduces the amount of defective products manufactured or services provided, resulting in increased revenue and greater customer satisfaction. Six Sigma identifies the cause(s) of your problem to efficiently develop effective solution(s). Six Sigma originated at Motorola in 1986 and since then has saved organizations billions of dollars in virtually every industry. Six Sigma reduces variation, so products or services can be delivered as expected reliably.  It uses a set of quality management methods, mainly empirical, statistical methods, and creates experts in these methods.

Lean and Six Sigma complement each other. Lean accelerates Six Sigma, delivering greater results than what would typically be achieved by Lean or Six Sigma individually.

Total Productive Maintenance (TPM) focuses on keeping all equipment in top working condition to avoid breakdowns and delays in manufacturing processes. One of the main objectives of TPM is to increase the productivity of plant and equipment with a modest investment in maintenance. In order for TPM to be effective, the full support of the total workforce is required. The eight pillars of TPM are mostly focused on proactive and preventive techniques for improving equipment reliability and productivity.

LEARNING OBJECTIVES

The course is designed as a very powerful pedagogic package interspersed with videos so that all related principles are captured as very important learning.

An understanding of the principles is essential for all – both in management and technical workforce.

This course will provide an overview of the concepts from:

• Lean manufacturing
• Total Productive Maintenance (TPM)
• Lean and Six Sigma

This course is ALSO part of the is a Bundled Specialization course titled Lean Manufacturing Tools Specialization.

After this course, the participant can appreciate any course on TPS or lean manufacturing which are at intermediate or advanced levels.

ALL of our courses in this series is developed based on decades of front-line industry experience of the instructor. 

WHO SHOULD TAKE THIS COURSE

Anyone who is involved with any process, be it manufacturing or transactional. Several TPS principles can be applied in any context. It is uniformly applicable across any function. This course is equally important to any operator or management staff, , especially a new employee

You might also want to consider  to take the course on Six Sigma Specialization along with this course.

COURSE CONTENT 

• INTRODUCTION
• LEAN MANUFACTURING
  • What & Why of Lean
  • What is manufacturing
  • A century earlier
  • Now – a century later
  • Lean manufacturing evolution
• PASSENGER CAR TRENDS
  • Passenger car trends
  • Engine Design
• TERMINOLOGY – KEY TERMS
  • Video – Overview
  • 5s
  • Andon
  • Muda – waste
  • Poka Yoke
  • Jidoka
  • Single-Minute Exchange of Dies (SMED)
  • Just In Time (JIT)
  • Value Stream Mapping (VSM)
  • Kanban
  • Heijunka
  • Kaizen
• TERMINOLOGY – UNDERLYING PHILOSOPHIES
  • Gemba
  • Plan-Do-Check-Act (PDCA)
  • Root cause analysis (RCA)
  • Takt Time
  • Visual Factory
  • Standard Work
  • Bottleneck analysis
• TPM
  • What is TPM
  • Unique feature of TPM
  • Why TPM
  • TPM Example #1
  • TPM Example #2
  • TPM Example #3
  • Results of TPM companies
  • TPM – 8 pillars
  • TPM Foundation
  • TPM Pillar #1
  • TPM Pillar #2
  • TPM Pillar #3
  • TPM Pillar #4
  • TPM Pillar #5
  • TPM Pillar #6
  • TPM Pillar #7
  • TPM Pillar #8
  • SUMMARY – TPM 8-Pillars
  • TPM – Recommended Implementation steps
  • TPM – Operator’s role
  • TPM – Hurdles for implementation
• LEAN SIX SIGMA
• SUMMARY
• REFERENCES & COURSE HANDOUTS
• FINAL QUIZ