Lean Manufacturing Tools Summary

Description

INTRODUCTION

This course on Lean Manufacturing Tools Summary 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.

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). For many, lean is the set of “tools” that assist in the identification and steady elimination of waste. As waste is eliminated quality improves while production time and cost are reduced. A non exhaustive list of such tools would 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). These concepts of flexibility and change are required to allow production levelling (Heijunka), using tools like SMED.

LEARNING OBJECTIVES

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

This course is designed to provide a quick familiarization of Lean Manufacturing Tools. We will familiarize you with the terminologies and the underlying philosophies of Lean Manufacturing.

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

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
• TERMINOLOGY – KEY TERMS
  • 5s
  • Muda – waste
  • Andon
  • Poka Yoke
  • Jidoka
  • Single-Minute Exchange of Dies (SMED)
  • Value Stream Mapping (VSM)
  • Just In Time (JIT)
  • Kanban
  • Heijunka
  • Kaizen
• TERMINOLOGY – UNDERLYING PHILOSOPHIES
  • Gemba
  • Plan-Do-Check-Act (PDCA)
  • Root cause analysis (RCA)
  • RCA – Examples
  • Takt Time
  • Visual Factory
  • Standard Work
  • Good Standard Work
  • Elements of standard work
  • Bottleneck analysis
  • Bottleneck analysis – more
• SUMMARY
• REFERENCES & COURSE HANDOUTS
• FINAL QUIZ