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LEAN MANUFACTURING
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Applying the Lean Manufacturing Technology to implement and run your factory as a flow.

Why should you attend this training ?

This training session enables you to gain a hands-on experience of how "Lean Manufacturing" technology can be practically applied. The goal of the class is to enable you to improve speed and response, quality, productivity and material requirements to respond very rapidly to the ever-changing customer demand.
The "Lean Manufacturing" technology can be applied to any kind of manufacturing process, regardless of its complexity. The steps to be taken to implement flow manufacturing, from customer order obtainment to product delivery, as well as the role of all corporate functions in this change, are clearly defined.

Target audience

Manufacturing Managers, Material Resource Managers, Manufacturing Engineers, Material Resource Engineers, Supply Chain Managers.
And any other manager or engineer from the other functions involved in the Lean Manufacturing project.

Goals

• Implement flow manufacturing in the plant to pull production based on customer demand until through to product delivery.
• Decrease manufacturing lead time and increase production capacity.
• Manufacture a mix of different products on the same line.
• Integrate quality control at every production step.
• Eliminate bottlenecks, reduce the level of WIP, finished products and working capital requirement.
• Develop a strategy to simplify activities, meet customer demand and achieve significant savings.

Main topics

Part 1 : Production in a traditional environment
• Traditional Production and Lean & Flow Production
• Working Capital

Part 2 : Organise a Demand Driven Flow Production // First tools of Lean Manufacturing
• Reduce Manufacturing Lead Time
• Value Stream Mapping
• Process Synchronisations
• Process Map
• Mixed-Model Process Synchronisation
• Sequence of Events
• Production based on Customer Demand
• Takt Time calculation
• Line Design calculations based on Takt Time
• Calculation of number of resources

Part 3 : Line balancing based on Takt Time
• Line Balancing Tools & Techniques
• Utilisation of IPK's (In Process Kanbans)
• Total Quality Control's
• Flexing of Operators
• Visual Graphical Instructions
• Critical Path

Part 4 : Implementation of Kanban Techniques and Supply Chain
• Kanban principles
• Inventory Strategy and stock reduction
• Material Resupply
• Kanban Techniques and Supply Chain
• Inventory Turns
• Kanban quantity calculations
• Backflush

Part 5 : How to integrate machines and upstream processes
• Balancing Techniques
• Machine cells
• Dual-Card Kanban

Part 6 : Optimisation of Resources in the organisation
• Impact on resources
• Linearity and Efficiency
• Training - certification of operators
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Educational approach

The theoretical portion of the training is reinforced by practical team workshops.
In our model factory, we simulate the various steps to implement a Lean & Flow Manufacturing environment which enable us to convert a traditional factory into a flow organisation. Participants learn by doing, starting to build products in the traditional way and, understanding by the second day of training, how to redesign the factory by applying the tools and techniques illustrated in the theoretical sessions.