Implementing Lean Methods to Reduce Cost and Improve Cashflow
Duration: 3 days
Target Audience: General Managers of production operations, Production Managers, Operations Managers, Process Managers, Senior Engineers, Business Analysts and Internal Consultants.
Key Learning Outcomes
- Learn how to plan, organise and implement Lean Techniques that will achieve increased throughput and revenue, improved quality, reduced cost and reduced lead times.
- Understand and analyse your operation allowing you to ‘mistake-proof’, and ‘future-proof’ your organisation.
- Critically analyse and engineer your organisation and processes, allowing you to remove waste, non-value-added activity and potential quality problems.
- Learn how to educate and involve your workforce in the process, achieving ‘buy-in’ and increased knowledge and understanding of the process.
Course Delivery Includes:
- Theory: Latest best practice
- Team discussions
- Individual and group exercises
- Case studies
- Technique application practice
- Business problem solving
- Personal action planning
Course Outline:Implementing Lean Methods to Reduce Cost and Improve Cashflow
DAY 1
Introduction to Lean Processes and Systems
History & Philosophy of Lean Processes and Systems
The Deming Cycle and TQM
Getting to grips with the Toyota Production System
Customer Orientation Considerations
Lean Tools & Techniques
Poka Yoke
Autonomation
Kaizen and Kaizen events
Kanban stocks, stores and buffers
Just in Time (JIT) techniques
‘Push’ and ‘Pull’ techniques
Planning and Scheduling
How to plan and schedule a lean manufacturing operation
Determination of Lot Sizes
Placement of a Constraint
Inventory and WIP
Process Mapping
Takt Time
Establishing a Continuous Flow System in a Non-Continuous Environment
Examining Value and Non-Value-Added Activities
Defining, Identifying and Eliminating Waste
DAY 2
Information and Measurement
Key Performance Indicators (KPIs)
The Visual Workplace and Sensory Signals
Statistical Techniques
An introduction to Six Sigma
Design of Experiment (DOE)
Feedback and control systems
Designing, Organising and Laying out the Workplace
Design for Assembly (DFA) and Design for Manufacturability (DFM)
5S Techniques
Standard Operating Procedures
How to observe, qualify and quantify work.
Elimination of the root causes of defects and quality problems
Machinery and Maintenance
Finding missing availability
Implementing Total Productive Maintenance
Measuring Overall Equipment Effectiveness
Understanding Reliability Centred Maintenance
DAY 3
Working with Suppliers
Developing partnerships
Moving away from traditional and damaging relationships
How to evaluate and communicate with a supplier
Make it Faster - Develop Speed
The relationship between quality and speed
Single Minute Exchange of Die (SMED)
Set-up time reduction and elimination
Pitfalls and practical tips on how to get it right.
Keys to Success
Useful tools, templates and measures
Factory layout principles
The importance of commitment and communication
Ensuring appropriate capability development of the team
Focused improvement for maximised results