Lean Manufacturing Workshop
As of Monday, November 12, 2018

This courseware provides participants with a comprehensive overview of LEAN manufacturing principles and best practices. The lessons learned can be immediately applied. These modules can be presented/facilitated in a one-day time frame and are ideal for company seminars and workshops with continuous improvement and the elimination of waste as goals.

1) Introduction to Lean Manufacturing
This workshop presents procedures companies use to identify and eliminate waste to become LEAN. It also covers topics such as the transparent workplace, lean process improvement, lean product development, Just-in-Time, controlling processes, and continuous improvement.

2) Lean Mapping
This workshop provides the tools for mapping a value stream. It gives the framework and provides the practical step-by-step guidance to recognizing value streams, current-state maps, future-state maps, and the action plan.

3) 5S Workshop
This workshop provides a foundation for delivering high-quality products and services in the right quantity, at the right time, to the right place to satisfy customer needs.

4) Process Improvement and Quality in Lean Manufacturing Workshop Objectives
This workshop discusses and defines the steps with the PDCA (Plan, Do, Check, Act) and DMAIC (the six-sigma: Define, Measure, Analyze, Improve, Control) frameworks and concepts of kaizen, root-cause problem solving, the visual factory/distribution center, the seven tools of quality, and blitz approaches.

5) Lean Scheduling Workshop
This workshop covers the essential tools for lean scheduling, including descriptions of building blocks and eight lean scheduling methods which include kanban, heijunka, and mixed-model production.

6) Standard Work Workshop
This workshop documents the steps of implementing standard work – a tool to determine maximum performance with minimum waste through the best combination of operator and machine.

7) Lean Teams, Lean Design, and Accounting Workshop
This workshop discusses lean team types, leadership skills, and anchor draggers. The lean design section covers concurrent design, value engineering, quality function deployment, and failure mode effects analysis.

Contact vp.education@apics-chicago.org . or 1-800-982-7427 for more information.

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Introduction to Lean Manufacturing

After completion of this workshop you will be able to
• Explain what a lean operation is and the benefits it provides
• Identify waste activities and understand why they should be eliminated
• Analyze a process using process flow analysis approach
• Understand popular lean manufacturing tools such as the 5 S’s, visual order and control, setup time reduction, manufacturing cells, use of takt time, standard worksheets, etc.
• List the benefits of incorporating lean concepts during the development phase of new products
• Explain what error¬ controlling devices are and how they can be used during production to reduce errors
• Understand what sigma quality concepts are, how to conduct kaizen blitzes, and why continuous improvement is important.

• Waste Elimination
• A Lean Improvement Methodology
• Leadership
• The Transparent Workplace
• Lean Process Improvement
• Lean Product Development
• Just¬ in¬ Time
• Controlling Processes
• Standard Work
• Continuous Improvement

Lean Mapping

• To introduce the basic mapping tools for lean analysis
• To understand when and how various mapping tools could be used
• To obtain a grounding on learning ¬to-¬see mapping
• To learn how mapping can be the basis of lean transformation

• Types of map used for lean
• Value¬ stream mapping
• How to identify your company’s value streams
• How to create a current state map
• How to develop other useful maps
• How to analyze a current state map and develop a future state
• A framework for lean implementation using mapping

5S Workshop

• Learn the benefits of 5 S
• Understand the definition and meaning of 5 Ss
• Learn the proper strategy for implementing a 5 S program
• Conduct 5 S exercises
• Apply 5 S principles at work

• Introduction to Lean Manufacturing
• Goal: Learn 5 S by Doing
• Definition of the 5 Ss
• Phase 1 of 5 S: Sort
• Exercise 1 – Tackle disorderliness and Lack of Cleanliness and Sorting in the Shop by Targeting Unneeded and Excess Items
• Discuss Sorting Observations/Opportunities for Implementing 5 S Projects
• Auditing a Shop for Sort
• Phase 2 of 5 S: Set in Order
• Exercise 2 ¬ Develop a New Layout for the Shop to Include Material, Equipment and Fixtures, and Location Indicators
• Discuss Set in Order Observations/Opportunities for Implementing 5 S Projects
• Auditing Set in Order
• Phase 3 of 5 S: Shine/Inspect
• Exercise 3 ¬ Identify and Develop a Plan for Shop Cleaning and Equipment Inspection/Maintenance
• Auditing Shine/Inspect
• Phase 4 of 5 S: Standardize

Process Improvement and Quality in Lean Manufacturing Workshop Objectives

• To illustrate the symbiotic relationship between lean and quality
• To appreciate the application of some quality techniques in a lean context.
• To appreciate how lean and six sigma can work together.

Workshop Topics
• Views from the Gurus
• The Lean View and Kaizen
• Problem Solving and PDCA
• Types of Defect
• Sporadic Problems: The Seven Tools and Five Whys
• Chronic Problems and Six Sigma
• Improvement Types
• Improvement Events (Blitz)
• Holding the Gains and Sustainability

Lean Scheduling Workshop

• Provide an overview of the central role of scheduling in a lean context
• Establish a framework for the implementation of a lean scheduling system
• Provide a working knowledge of core lean scheduling techniques.

Workshop Topics
• Frameworks for lean scheduling
• Relationships between lean and MRP, APS, and TOC
• Managing queues and flow
• The effects of variation (statistical fluctuation and dependent events)
• Building blocks for lean scheduling
• Eight lean scheduling ideas: (pull and kanban, takt time, runners repeaters strangers, the pacemaker, mixed model scheduling, level scheduling and heijunka, batch sizing, demand stabilization)
• A brief look at CONWIP and POLCA

Standard Work Workshop

• Understand the elements and methods of standard work
• Understand cellular manufacturing
• Conduct time observations, process capacity studies, and team activities related to standard work
• Prepare standard work documents

• Introduction to Standard Work
• Capacity Concepts
• Cellular Manufacturing
• Standard Work Elements

Lean Teams, Lean Design, and Accounting Workshop

• To provide an overview of the role teams, measurements, and design have in contributing to success in lean implementation
• To review relevant current theories on teams, accounting, and design as they relate to lean

• Team and Leadership Models for Lean
• Lean Measurements
• Lean Accounting and Costing
• Lean Design Considerations
• Modularity and Platforms



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