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Lean Manufacturing Essentials     5-Day Programme     £1650+VAT	Dates Available 2010 Dates: June 28 - July 2 (Leamington Spa) August 23 - 27 (Leamington Spa) October 25 - 29 (Leamington Spa)
Massive benefits can be gained by concerted and systematic efforts to eliminate waste, improve process performance, speed up product flow and change unproductive practices. This exclusive fast-track Lean EssentialsTM programme provides a structured approach to Lean Manufacturing, and focuses on the key tools and techniques needed by improvement project leaders. Practical exercises and case studies are used throughout the programme to reinforce the learning, and companies can use the powerful Lean EssentialsTM approach to create an improvement ‘taskforce’ – skilled to develop the business to even higher levels of performance. The Lean EssentialsTM 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.
Course Content
Day 1 Lean Manufacturing & Waste Elimination •Intro to Lean •Waste elimination •Performance measurement •Continuous improvement (Kaizen) 5S Workplace Organisation & Visual Management •Sort, straighten, sweep, system, sustain •Creating a visual workplace •Standard operating procedures Day 2 Structured Problem Solving •Developing a structured approach •Identifying & prioritising improvement projects •Team formation & action planning •Data collection •Analysing the facts & establishing root causes •Creative solution generation •Pilot testing & validation •Formal adoption of solutions •Performance review Day 3 Optimising OEE & TPM •Total Productive Maintenance (TPM) •Measuring & improving Overall Equipment Effectiveness (OEE) •Autonomous Maintenance Effective Team Working •The dynamics & process of change •Building commitment to change •Leading, building & coaching improvement teams Mistake Proofing (Poka Yoke) •Objectives of mistake proofing •Errors & defects •Systems for achieving zero defects •Mistake proofing in manufacture, design & the office Day 4 Rapid Changeover Techniques (SMED) •Rapid changeovers & competitive advantage •Terminology & targets •Changeover analysis •Changeover reduction exercise Value Stream Mapping •Benefits of mapping the value stream •Current state mapping •Identifying improvement opportunities Day 5 Making Products Flow •‘Just in Time’ principles •Pull vs. Push systems •One-piece flow & Kanban systems •Layout considerations •Cellular manufacturing •Standard operations & balancing to TAKT time •Future state mapping & implementation Factory Simulation Course Summary and Review