Teaches basic concepts and philosophy of lean, history of lean, and basic tools of lean. Gives an understanding of waste and flow and how to identify improvement opportunities.
Understanding, teaching, and applying lean to establish a learning organization with an emphasis on the role of leaders to create, implement, and sustain change in an organization. This module is fundamental to any initiative as 75% of the change is behavioral, and 25% is tools/technique.
5S and Visual Controls
5S is the process of removing waste, getting organized, cleaning and creating a culture that sustains these. Visual Controls (VC) is the process of bringing clarity to an operation in terms of what to do, where things belong, and when corrective action is required. 5S and VC reduce non-value added time in any product service delivery process.
Set up Reduction
The process of reducing the time, waste, and variability it takes to switch a process from making the last good part of product A, to the first good part of product B. Also known as changeover reduction, includes reducing clean up time in a process. Reducing changeover time is an enabler to lot size reduction, inventory reduction, and mixed model scheduling.
The production and movement of items based on the their usage in consuming operations. Kanban provides the signal and information required to replace what was consumed. This concept helps to improve flow of material and people, and signal replenishment/production of only what is needed.
Standard Work Implementation
The process of establishing the documented current best method to safely and efficiently perform work that meets the necessary level of quality. Included is the process to implement and sustain standard work which allows waste to be identified and removed, forming the basis for all improvement.
The method of analyzing the rate of production (machine time and manual work content) of each operation and minimizing wait time and inefficiency in order to maximize throughput.
Value Stream Mapping
The process of drawing material and information flow across all organizations required to produce a product or family of products. Process data and cycle time are collected for each step of the process with a focus on reducing cycle time as well as non-value added activities.
Total Productive Maintenance
The process of analyzing equipment downtime (into the 6 major losses) with the goal of maximizing equipment available time - allowing equipment to be ready to produce when needed.
The quality focus of TPS to ultimately produce zero defects. The principle of separating the human work from the machine work, creating a process where abnormal conditions are identified and responded to immediately, never passing a known defect. Layers of Quality and MP/FS are part of the Jidoka philosophy.
FMEA and Layers of Quality
Failure Mode Effect Analysis (FMEA) is identifying and ranking potential problems, as well as defining and ranking countermeasures to each potential problem. Layers of quality is applying 5 layers of "protection" to guard against the creation of a defect as identified in the FMEA process, with a focus on eliminating mistakes (or making mistakes visible). Layers of quality can also be applied as layers of safety.
Mistake Proof/Fail Safe (MP/FS)
The use of practices that make it difficult or impossible to do a task wrong, and easy to do the task correctly. The goal of fail safe is to minimize the consequences if something goes wrong. The intent is to apply MP/FS at the source (before operations take place) to ensure the right conditions are present for a successful operation.
Line Design/Cellular Flow
An approach to manufacturing that allows the production of a variety of products with as little waste as possible. Cellular flow gives companies the flexibility to give customers the variety they want. Workstations are arranged in a sequence that supports a smooth flow of materials paced to takt, that are pulled through the process with minimal transport and delay.
Lean Product/Process Development
Product and process design to support lean concepts. Assures quality, takt, flow and pull are built into the process, and the products are designed for ease of manufacturing. Mock ups are created that allow new designs (by a creative look at nature) to be evaluated. The process starts with concept and is completed with an accredited manufacturing process. This is an iterative process going through study/creativity followed by trials (kaizen) typically extending over a year.