Duration
2 days
Overview
One of the greatest challenge to today's industries and companies is how to change the way how to minimize waste while maximizing productivity and quality. A sustainable lean culture has to be created in order for staff to function well in Lean manufacturing.
To achieve this, our employees must be well equipped with the right knowledge and method to work towards reducing waste and improving factory efficiency and effectiveness. Lean manufacturing will expose our manufacturing personnel towards a more systematic and efficient way of reducing wastes and improving the overall delivery system. This also includes building and sustaining a culture of continuous improvement.
Various case studies will be given to illustrate the application of the Techniques learnt.
At the end of the programme, the participants will be able to apply Lean concepts to:
- Eliminate wasted time and resources
- Build quality into workplace systems.
- Find low-cost but reliable alternatives to expensive new technology
- Perfect the business process
- Building a learning culture for continuous improvement
Module 1: Introduction to Lean Manufacturing
- The Lean concept and Toyota Production System
- The 14 Lean Manufacturing Principles
- Preparing your factory for Lean
- The 8 Wastes of Production
- The long term philosophy of Lean
Module 2: Continuous Flow and Pull Manufacturing
- Create a continuous flow process to bring problems to the surface
- Cellular manufacturing and benefits of the work cell
- Create a "pull" production system to avoid over production
- Implementing Kanban
Module 3: Heijunka - Levelling out the Workload
- Smooth out your production volume to avoid Mura and Muri
- Heijunka by product and Heijunka by volume
- Apply Single Minute Exchange of Dies (SMED) to reduce product changeover or machine setup time.
- Apply Total Productive Maintenance (TPM) to reduce unnecessary downtime .
Module 4: Apply Jidoka and Poka Yoke to improve the quality
- Apply Jidoka or line-stop measures to stop line when problems are discovered. Do It First Time Right concept.
- Apply Poka Yoke or mistake proofing by preventing or detecting defects.
- Standadize tasks to provide opportunity for continuous improvement.
- Use visual controls and Andons to identify the status of a process and to bring out hidden problems.
Module 5: Sustaining and Growing the Lean movement
- Use reliable technology
- Grow leaders that will bring Lean to the next level
Invest in people development, team development, supplier and partner development to grow and sustain Lean.
Module 6: Implementing Lean
- Guide to the successful implementation of lean program
- Roles and responsibility of the different personnel in Lean Manufacturing
- Pitfalls to avoid in Lean implementation
Programme scope, delivery arrangements and suitability are confirmed during enquiry.