MANUFACTURING LEAN BELT

Commences October 25th 2010 (Leamington Spa)

£1500+VAT per delegate

inclusive of:

• Comprehensive training manual

• Lunches and refreshments

4book places

INTRODUCTION

This training will provide Lean leaders and practitioners with the confidence and tools to lead practical Lean improvement activities in their companies. Participants will leave the training skilled and ready to deliver measurable benefits back to their business through the elimination of waste, improved process performance, and more efficient product and process.

They will be able to identify and scope a range of improvement activities that can be cascaded through different levels of the organisation. The training content also includes the key facilitation skills to help Lean Belts lead small teams in practical mapping and waste elimination activities. Practical exercises and case studies are used throughout the programme to reinforce the learning.

This programme is also available on an in-company basis, and can be tailored to suit specific needs, incorporating shop floor improvement activities as appropriate. Additionally, a certificated ‘Lean Facilitator’ package is available to delegates wishing to undertake a Lean improvement project with guidance from an experienced Smallpeice coach.

ACCREDITATION

The Smallpeice accreditation process for Manufacturing Lean Belts is based on the review and assessment of a series of practical improvement projects.

LEAN FOUNDATIONS

ANALYSING THE VALUE STREAM CURRENT STATE

October 25th

October 26th

October 27th

October 28th

October 29th

Lean Basics

Lean Sigma Approach

• Lean Thinking

• Understanding Value and Waste

• Linking Lean and Six Sigma: The Lean Sigma Approach

Building a Lean Foundation

• Waste Walking

• Creating a visual workplace

• 5S Workplace Organisation

• Use of Standard Work

• Mistake Proofing

Tools for Identifying and Eliminating Waste

• Process Mapping Tools Revisited

• Process Sequence Charts

• Spaghetti Charts

• Introduction to Value Stream Mapping

Understanding the Current Value Stream

• Defining value streams

• Organising by value stream

• Developing the current state Map

• Mapping transactional processes

Analysing the Current State

• Balancing load and capacity

• Finding and analysing bottlenecks

• Cycle time and workload analysis

• Work in process and Lead time analysis

Introduction to Total Productive Maintenance

• Objectives of TPM

• Measuring Overall Equipment Effectiveness

• Autonomous maintenance

• Developing TPM standards

Rapid Changeover

• The concepts of SMED

• Internal vs external work

• Recording the changeover process

• Techniques for converting internal  to external

• Changeover simulation activity

• The Concept of Jidoka

Steps for Creating a Future State Map

• Creating a Lean Vision

• Developing a 'must be' list

• Step by Step guide to developing the future state map

• Strategies for Creating Continuous Flow

• Push versus Pull Systems

WIP Control Strategies

• Material Flow Control

• Use of Kanban and CONWIP systems

Developing the Improvement Plan

• Identifying manning and skills requirements

• Developing the improvement plan

Barriers to Developing Flow

• Dealing with fluctuations in customer demand

• Dealing with physical constraints

• Dealing with non repetitive work & creating flow

• Scheduling non repetitive work flows

Creativity Techniques

• The role of creativity in Lean Thinking

• Barriers to creative thinking

• Creative Thinking Tools

• Links to Future State mapping

Facilitating Value Stream Mapping Activity

• Planning mapping activity

• On the day – dealing with facilitators nightmares

• After the event – implementing and sustaining the improvement