DESCRIPTION:
The Lean Operations Design Workshop shows how to evolve Lean transformation from an isolated improvement approach to transforming plant production systems by implementing a Lean production control system.
The course will develop step by step the stages to implement continuous flow, level production and pull.
GOALS:
At the end of the training, participants will be able to develop a Lean production control system.
CONTENTS:
INTRODUCTION – PRODUCE FOR THE TAKT
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MONITORING 1 – CONTINUOUS FLOW
- Takt analysis review.
- Continuous flow.
- Suitable products.
- Identification of work elements.
- Automation Levels.
- Distribution of Physical Space.
- Calculation of Operators.
- Cell Design.
CONTINUOUS FLOW WORKSHOP
- Collection of the information necessary for the analysis.
- Paper Kaizen.
- Implementation Gemba walks.
TRACKING 2 – PULL
- Gemba Walks to Review Implementation Progress.
- Construction of Supermarkets.
1- ABC of products.
2- Supermarket size calculation.
3- Supermarket Organization.
PULL WORKSHOP
- Collection of information for construction of supermarkets.
- Paper Kaizen.
- Implementation Gemba Walks.
FOLLOW-UP 3 – PACEMAKER
- Pull Implementation Progress Review Gemba Walks.
- Pacemaker.
- Where to program the value chain?
- How to level production?
- How to level the pacemaker?
- How to transfer the demand to the step-by-step process?
PACEMAKER WORKSHOP
- Collection of information for definition of pacemaker
Paper Kaizen.
Pacemaker Implementation Gemba Walk.
FOLLOW UP 4 – HEIJUNKA
- Pacemaker implementation progress review gemba walks.
- Heijunka.
- Pitch.
- Construction of the Heijunka.
HEIJUNKA WORKSHOP
- Collection of information for definition of hejunka.
- Paper Kaizen.
- Heijunka Implementation Gemba Walk.
MONITORING 5 – UP CHAIN PROCESSES
- Heijunka Implementation Progress Review Gemba Walks.
- Batch processes.
- Production Control in processes upstream of the Pacemaker.
- Production control of processes in batches upstream of the pacemaker.
UP CHAIN PROCESSES WORKSHOP
- Collection of information to define upstream processes
- Paper Kaizen
- Upstream Process Implementation Gemba Walk
This course grants 8.00 recertifiable units (RU's) applicable for recertifications in CQE and CMQ/OE of the ASQ
English 
Spanish