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.

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

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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.