DESCRIPTION:
 

The Lean Operations Design Workshop shows how to evolve Lean transformation from a stand-alone approach to improvements to transforming plant production systems by implementing a Lean production control system.

The course will develop step by step the steps to implement continuous flow, level and pull production.

OBJECTIVES:
At the end of the training, participants will be able to develop a Lean production control system.
 
CONTENTS:

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  • Review of Takt analysis.
  • Continuous Flow.
    • Suitable products.
    • Identification of work elements.
    • Automation Levels.
    • Physical Space Distribution.
    • Calculation of Operators.
    • Cell Design.
  • Collection of the information necessary for the analysis.
  • Paper Kaizen.
  • Gemba implementation walks.
  • Gemba Implementation Progress Review Walks.
  • Construction of Supermarkets.
    1- ABC of products.
    2- Supermarket size calculation.
    3- Supermarket organization.
  • Information gathering for the construction of supermarkets.
  • Paper Kaizen.
  • Gemba Implementation Walks.
  • Gemba Pull implementation progress review walks.
  • Pacemaker.
    • Where to program the value chain?
    • How to level production?
    • How to level the step marker?
    • How to transfer the demand to the process marks steps?
  • Information gathering for pacemaker definition
    Kaizen Paper.
    Pacemaker Implementation Gemba Walk.
  • Gemba Pacemaker implementation progress review walks.
  • Heijunka.
    • Pitch.
    • Construction of the Heijunka.
  • Collection of information for hejunka definition.
  • Paper Kaizen.
  • Heijunka Implementation Gemba Walk.
  • Gemba walks to review progress of Heijunka implementation.
  • Batch processes.
    • Production Control in upstream Pacemaker processes.
    • Batch process production control upstream of the pacemaker.
  • Gathering of information for upstream process definition
  • Paper Kaizen
  • Gemba's upstream process implementation walk

This course awards 8.00 recertifiable units (RU's) applicable for ASQ CQE and CMQ/OE recertification.