LEAN MANUFACTURING 
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How to produce multiple models on one production line.  Introduction
The advanced workshop for “Lean Manufacturing” teaches the tools & techniques indispensable for the implementation and the management of a demand driven production environment producing multiple models.
The workshop is focused on the design of advanced flow lines, process mapping, time indexation, value added time analysis and the design of dual-card Kanban systems. Other subjects covered are the sequencing of production when producing multiple models, producing on demand, Production and flow line balancing, the use of flexible employees and the organization and daily management of a flow line.
The participants learn how to design a flow line or cell and how to overcome potential obstacles once implementing the tools & techniques. What you get from this unique workshop ? The participants being placed in a real life situation !
The workshop format has a functional approach, supported by a practical workshop unique of its kind.
The participants, placed in real life situation in our model factory, have to develop the necessary tools and line design calculations at each stage for the development of the flow line using information tools being provided by REOSS resulting in the demand driven production of multiple models. WORKSHOP Objectives • Provide to the participants the necessary tools & techniques for the effective implementation of a mixed-model flow line.
• Learn the different methods to balance lines and eliminate bottlenecks.
• Learn how the manage flow lines driven by customer demand.
• Learn how to daily organize and manage flow lines. Workshop Content The workshop is focused on the development of a flow environment producing different models and is presented in the following order : Part 1 : Summary of the first Lean & Flow Manufacturing tools & techniques presented in the Base Workshop. Part 2 : The fundaments
- Analysis of Vpast et Vmax
- Define correctly Vmax
- Define Effective Hours Part 3 : The Lean Tools for a Multiple Model Environment
- Process Synchronisation: Integrating scrap, rework, control in the Vmax calculation
- Process coding in a Process Map
- SOE : Balance operation based on Takt Time
- Family definition
- Cell design in a process
- Process MAP : Smoothing demand and operator staffing
PRACTICAL WORKSHOP (Line design calculation Physical implementation) Part 4 : Material and material resupply
- Single Card Kanban : Development of a Kanban Master in Excel
- Calculation of Dual Card Kanban
- How to initialise a flow line with material
- How to distribute the customer orders in a Mixed-Model Flow Line
PRACTICAL WORKSHOP (Kanban Implementation Production of Multiple Model) Part 5 : Organise Manage a flow line
- Short Interval Management
- Organisation of a Lean environment
- Continuous Improvement
- Cyclic Management Events Part 6 : Flow Line Formalisation
- Flow Line Formalisation (after the implementation)
- Strategic Commercial approach on delivery times THE Benefits to your company After this workshop each participant will be able to develop a mixed-model flow line, manage this new flow line and provide his company the means to increase profitability by using this new way of producing. Who should attend ? It targets an audience involved in process improvement and the implementation of “Lean Manufacturing”. It’s an indispensable workshop for those who are person responsible a “Lean Manufacturing Programme”.
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