Duration
10 days
Overview
Course aim
The first step in making an operational transformation is developing Change Agents to drive this initiative. These Change Agents are called Lean Experts.
Course description
This training will equip participants with the practical knowledge on how to carry-out Lean initiatives to the shopfloor. It takes participants through in detail the philosophies, principles and techniques of Lean. In addition, participants are also taught the details of initiating continuous improvement projects, project management and how to deal with implementation and change issues.
How will I benefit?
This programme provides the foundation for the Lean Expert to :
- Understand the contents of Lean initiatives – philosophy, principles and techniques
- Lead and manage Lean improvement teams to enhance shopfloor performance
- Train team members on Lean initiatives
- Establish key performance metrics to monitor progress and results attained
- Identify key improvement opportunities and resolve issues
- Replicate Lean initiatives on factory-wide operations.
What will I learn?
Upon completion of the programme, participants would be able to:
- Explain Lean principles and techniques
- Follow the techniques of each Lean tool (in the syllabus) and apply them in initiating, leading and managing improvement projects
- Recite the respective lean tools in details (objective, purpose and application)
Who should attend?
Managers, Engineers, Maintenance and Production Professionals and personnel responsible for production capacities, flexibility and responsiveness to meet demand.
Duration
This is a 10-day course running from 9.00 am to 5.00 pm each day and is spread over 2 Flights
How will I learn?
The programme will be facilitated by experienced trainers who are also certified Lean Masters. Profile of the trainer will be sent to participants prior to each workshop. Our experienced tutors have practical application of the subject matter, enabling them to understand and meet your specific requirements.
Agenda
Lean Expert - Flight 1
Day
Time
Details
Day 1
09.00 am – 09.30 am
Opening and Introduction (Trainer & Participants)
Introduction to the Lean Expert programme
09.30 am – 10.30 am
Lean Manufacturing Value Stream Improvement
An Introduction to Lean
Why should organizations go Lean
10.30 am – 10.45 am
Morning Tea Break
10.45 am – 12.30 pm
Value Versus Waste 7 Operational Wastes
Principles to Lean transformation
12.30 pm – 01.30 pm
Lunch
01.30 pm – 03.30 pm
Overview of Lean tools and techniques
03.30 pm – 03.45 pm
Afternoon Tea Break
03.45 pm – 05.00 pm
Lean Simulation Workshop
Day 2
09.00 am – 10.30 am
Value Stream: Unlocking your Process Value Stream Tools
- Spaghetti Diagram
- Process Flow Activity
10.30 am – 10.45 am
Morning Tea Break
10.45 am – 12.30 pm
Workshop on spaghetti diagram and process flow activity
Learn to See - Current State
12.30 pm – 01.30 pm
Lunch
01.30 pm – 03.30 pm
Workshop on Current State
Improvement from Current to Future State
03.30 pm – 03.45 pm
Afternoon Tea Break
03.45 pm – 05.00 pm
Performance metrices from the value stream Summary and Q&A session
Day 3
09.00 am
–
10.30
am
Work Engineering for Smooth Flow Manufacturing
Session 1 : Introduction to Work Engineering Session 2 : Work Method study
Motion study and Process Study
10.30 am
–
10.45
am
Morning
Tea Break
10.45 am
–
12.30
pm
Session 3 : Principles and Tools to improve work method
- Principles of motion economy
- ECAS
Session 4 : Work Measurement
- Time Study - Normal time and Standard Time
- Work sampling - Normal time and Standard Time
- Cycle Time, Takt Time, and Lead Time
12.30 pm
–
01.30
pm
Lunch
01.30 pm
–
03.30
pm
Session 5 : Applications of IE Work Study
- Determine manpower
- Line Balancing (Yamazumi chart)
Session 6 : Developing the preferred method
- Work Element Analysis
- Multiple Activities Chart
03.30 pm
–
03.45
pm
Afternoon tea break
03.45 pm
–
05.00
pm
Day 4
09.00 am
–
10.30
am
Session 8 : Standardized Work
- Standard Work Sheet
- Standard Work Combination Sheet
10.30 am
–
10.45
am
Morning
tea break
10.45 am
–
12.30
pm
Session 9 : Introduction to Smooth flow
- Purpose and benefits of flow based manufacturing
- Smooth Vs Disruptive Flow
Session 10 : Smooth Flow Manufacturing
- Types of assembly line layouts
12.30 pm
–
01.30
pm
Lunch
01.30 pm
–
03.30
pm
Session 10 : Smooth Flow Manufacturing (Con’t)
-Cellular Manufacturing (work cell design and planning)
- - Cell cycle time and capacity
Session 11 : Types of Flow Patterns
03.30 pm
–
03.45
pm
Afternoon tea break
03.45 pm
–
05.00
pm
Day 5
09.00 am – 10.30 am
Kaizen Implementation
Session 1 : The background of Kaizen concept
- What does ‘kaizen’ mean
- the objective of Kaizen
Session 2 : Project Selection and Kaizen Metrics Session 3 : Two approaches to carry-out kaizens
- Kaizen Event
- Workplace Kaizen (Small Group Activities)
10.30 am – 10.45 am
Morning Tea Break
10.45 am – 12.30 pm
Session 4 : Organizing Kaizen Event :
- Kaizen Event Timeline
- Preparation: Project Charter
- Step-by-step guidelines with Kaizen Workbook
Session 5 : Organizing Workplace Kaizen (Small Group Activity)
- SGA Workbook
Session 6 : Calculating financial savings:
- Hard Savings
- Soft Savings
- Net Working Capital
12.30 pm – 01.30 pm
Lunch
01.30 pm – 03.15 pm
Flight 1 Lean Knowledge Assessment
03.15 pm – 03.30 pm
Afternoon Tea Break
03.30 pm – 05.00 pm
Flight 1 Lean Knowledge Assessment Course Summary
Lean Expert – Flight 2
Day
Time
Details
Day 1
09.00 am – 10.30 am
Training Within Industry
Introduction to Training within Industry (TWI) The 5 Needs Model for the Supervisor Demonstration of different training methods
10.30 am – 10.45 am
Morning Tea Break
10.45 am – 12.30 pm
Demonstration of different training methods Job Instruction: The 4-step method
Preparing to Instruct (4-step)
12.30 pm – 01.30 pm
Lunch
01.30 pm – 03.30 pm
Group workshop: TWI Job Breakdown Sheet
03.30 pm – 03.45 pm
Afternoon Tea Break
03.45 pm – 05.00 pm
Job Method: The 4-step method
Job Relations : The 4-step method Summary and Q&A
Day 2
09.00 am – 10.30 am
Quick Changeover for Operational Flexibility and Responsiveness
Introduction, Purpose and Benefits of Quick changeover
10.30 am – 10.45 am
Morning Tea Break
10.45 am – 12.30 pm
Approach to Quick changeover The 6 Steps of Quick changeover
Exercise 1
12.30 pm – 01.30 pm
Lunch
01.30 pm – 03.30 pm
The 6 Steps of Quick changeover (con’t)
Exercise 2
03.30 pm – 03.45 pm
Afternoon Tea Break
03.45 pm – 05.00 pm
Beyond the 6 Steps Summary
Q&A
Day 3
09.00 am – 10.30 am
Total Productive Maintenance (TPM): Key to Production Effectiveness
TPM vs Traditional Maintenance The 8 Pillars of TPM
Pillar 1: Focused Improvement Pillar 2: Autonomous Maintenance
10.30 am – 10.45 am
Morning Tea Break
10.45 am – 12.30 pm
Activity session: Autonomous Maintenance checklist Pillar 3 : Planned Maintenance
Pillar 4: Technical Training
Pillar 5: Early Equipment Management
12.30 pm – 01.30 pm
Lunch
01.30 pm – 03.30 pm
Pillar 6 : Quality Maintenance Pillar 7: TPM Office
Pillar 8: Safety Health and Environment
TPM Implementation Roadmap
03.30 pm – 03.45 pm
Afternoon Tea Break
03.45 pm – 05.00 pm
Overall Equipment Effectiveness (OEE) Summary and Q&A
Day 4
09.00 am – 10.30 am
Zero Defects through Poka Yoke
Introduction to Poka Yoke Zero Defect Quality Concept
10.30 am – 10.45 am
Morning tea break
10.45 am – 12.30 pm
The 6 principles of error-proofing
Discussions
Poka Yoke methods
Session 6: Poka Yoke device for automated process
03.30 pm – 03.45 pm
Tea break
03.45 pm – 05.00 pm
Session 7 : Poka Yoke implementation with root cause analysis
Summary and Q&A session
Day 5
09.00 am – 09.30 am
Recap of Flight 2 topics
09.30 am – 10.30 am
Flight 2 Lean Knowledge Assessment : Exam
10.30 am – 10.45 am
Morning Tea Break
10.45 am – 11.15 pm
Con’t - Flight 2 Lean Knowledge Assessment : Exam
11.15 am – 12.30 pm
Recap of Flight 1 topic - Value Stream Mapping
12.30 pm – 01.30 pm
Lunch
01.30 pm – 03.30 pm
Flight 2 Lean Knowledge Assessment : Value Stream Mapping Analysis
03.30 pm – 03.45 pm
Afternoon Tea
03.45 pm – 05.00 pm
Flight 2 Lean Knowledge Assessment : Value Stream Mapping Analysis
Cont’
Q & A
Training (Certificate of Attendance)
- Completion of Lean Expert Training with a minimum attendance of 90% per Flight (NOT accumulation of 2 flights)
Certification Criteria (Certified Lean Expert)
- Completion of Lean Expert Training with a minimum attendance of 90% per Flight (NOT accumulation of 2 flights)
- Pass all the Exams (both flights),
- Pass the Value Stream Analysis Assessment (Flight 2)
- Completion of 1 Lean project with application of at least 1 Lean tool from the 2 flights
- Project Report submitted to and approved by BSI trainer
- Project savings / benefits achieved to be validated and endorsed by participant’s organisation, as real gains.
Note:
Participants must be involved and contribute to the Lean Project. Activities that fulfil this criteria:
- Participant is a project team leader or team member
- Participant contributes ideas on Lean tool application
- Participant is involved in data collection, analysis and solution implementation
Each Lean Expert participant will be given a period of 12 months from completion of the Flight 2 training to complete one Lean project for submission and certification.
Programme scope, delivery arrangements and suitability are confirmed during enquiry.