Excel College's Corporate & Executive Training Programmes

 

LEAN MANUFACTURING
BREAKTHROUGH TECHNIQUES

Continuous improvement and eliminating waste are fundamental principles in Lean Manufacturing systems. Lean Manufacturing is based on setting standards aimed at continuous improvements by all team members through constantly eliminating waste. It is an opportunity to change a flabby waste-filled operation into a toned and muscular manufacturing company.

This program is an antidote to stagnation and to leap beyond today's best practice. This workshop provides a new manufacturing Diet.

OBJECTIVES
  • Manufacturing velocity analysis.
  • Flow system manufacturing by simulation.
  • Cycle Time reduction by simulation.
  • Waste reduction by simulation.
  • Inventory and space reduction by simulation.
  • Strategic supply chain management.
METHODOLOGY
40% Lectures
60% Simulations

WHO SHOULD ATTEND
Senior manufacturing executive / managers
Operating managers
Materials and/or quality managers
First level supervisors
Manufacturing or industrial engineers
Training managers

WORKSHOP DESCRIPTION
This workshop must be attended if your manufacturing operations need to become more responsive to your customer's needs. You will be introduced to the many concepts that fall under the umbrella of lean manufacturing, more so you will also get tangible ideas that you can take back to work and implement. For example, you will learn how to reduce cycle time and how to use workflows to develop effective and efficient plant layouts. In addition, you will discover how cellular operation concepts can increase your productivity and deliver results that will enhance your bottom line.

WORKSHOP OUTLINE:

    DAY 1
  1. Linkage of Supply Chain Management (SCM) & Lean System
    A conceptual framework
    SCM for Global competitiveness
    Strategic issues in supply chain
    Corporate profitability and supply chain

  2. Application of knowledge Management for effective supply chain management in a dynamic business environment.

  3. Traditional Manufacturing Systems
    Departmentalization
    1st Simulation (10 mins.) (Not Lean)
    - participants will take part in some assembly operations performed in a traditional
    way
    - end of simulation calculate the group's performance
      ° lead time
      ° quality
      ° productivity
      ° inventory

  4. The Lean Principles
    Lean Mission
    Lean Revolution
    Value Revolution
    Lean Commitments

  5. Manufacturing Velocity
    Choose one of your product, calculate ratio of value added activities to your lead-
    time.

  6. The 7 wastes

    DAY 1
  1. 2nd Simulation (rearrangement of assembly line)
    reduction of manpower
    elimination of departmentalization
    introduction of cell concept
    end of simulation calculate the group's performance
      ° lead time
      ° quality
      ° productivity
      ° inventory

  2. Lean Tools
    The flow system
    The pull system
    Quick changeover
    Mistake proofing (Poka Yoke)

  3. 3rd Simulation (10 mins)
    practice Kanban
    reduction of lot size
    end of simulation calculate the group's performance
      ° lead time
      ° quality
      ° productivity
      ° inventory

  4. Elimination of non-value add activities and balance the line
    Is inspection value add activity?
    Is warehousing a value add activity?
    A case study will be introduced

  5. 4th Simulation (Lean) (30 mins)
    The group to design their own assembly using formula learnt
    The groups to eliminate all non-value add activities in their process and set up a
    lean line
    end of simulation calculate the group's performance
      ° lead time
      ° quality
      ° productivity
      ° inventory
    participants to compare the results of 1st, 2nd, 3rd and 4th. simulation to make an evaluation of what is value add and non-value add in your organization.

Program Code: 2-1000-02