| Value
Stream Mapping
Value-stream maps are the road maps for lean transformations.
This workshop shows you how to make and apply this fundamental and
critical tool. The value-stream map is a paper-and-pencil representation
of every process in the material and information flow, along with
key data.
Through the workshop you will learn to see value,
differentiate value from waste, and eliminate the sources of waste
by creating accurate current-state maps and leaner future-state
maps for a product family. It can be applied to your company’s
product family to achieve the following.
- Benchmark current state
- Establish a direction for the company’s
improvement efforts
- Target kaizen activities for moving towards your
future state improvements
- Create the basis for an effective lean implementation
plan by designing how a facility’s door-to-door material
and information flow could operate.
- Give operators, engineers, and managers a common
language and process for continuous improvement.
This workshop will sharpen your "eyes for waste"
and "eyes for flow." Using a manufacturing case study
and then expanding it to your own product family value stream (optional)
you'll learn how to identify a product family, how to see the entire
value stream for a particular product family, how to map the value
stream to identify and eliminate waste, what makes a value stream
lean, and how to develop a plan to achieve results.
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Executive Lean
Enterprise Overview Training
This training program provides an overview of what
a Lean Enterprise is. It includes definitions and short discussions
of a lean enterprise, waste identification and waste elimination.
The course also focuses on the tools utilized by a lean organization.
These include defining and examples of Value-Stream Mapping; Accelerated
Cycle Time Reduction; Process Mapping; Pull / Kanban; Cellular /
Flow; Total Preventive Maintenance; Quality at Source; Pont of Use
Storage; Quick Changeover; Standardized Work; Batch Reduction; Use
of Teams; 5 S Systems; Visual Management; Kaizen Planning and Plant
Layout. The course will also provide the lean enterprise implementation
process and how to get results.
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Employee Lean
Enterprise Overview Training
This training program provides an overview of what
a Lean Enterprise is. It includes definitions and short discussions
of a lean enterprise, waste identification and waste elimination.
The course also focuses on the tools utilized by a lean organization.
These include defining and examples of Value-Stream Mapping; Accelerated
Cycle Time Reduction; Process Mapping; Pull / Kanban; Cellular /
Flow; Total Preventive Maintenance; Quality at Source; Pont of Use
Storage; Quick Changeover; Standardized Work; Batch Reduction; Use
of Teams; 5 S Systems; Visual Management; Kaizen Planning and Plant
Layout. The course will also focus on “Why I would want to
do this?”, “What’s in it for me?”, and “How
will it effect the company and our customer?”. Time for questions
will be provided.
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Lean Enterprise
Overview Training With Simulation
This training program will not only teach the lean
enterprise tools but also engage your team in a simulation exercise
to bring a company back to profitability and meet customer demands.
The trainees will engage in building a product using past or conventional
methods. They will then learn lean tools such as waste identification
and elimination, facility layout wastes, continuous flow and apply
them to their simulation company to not only bring the company out
of the RED but also improve the work environment and satisfy the
customer. The class is eight hours in duration and requires a minimum
of 12 participants.
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Visual Systems and
5S
Visual systems provide effective tools to support
visual performance management with a self-reporting and self-reinforcing
workplace. Visual systems communicate schedule and performance data
to the total workforce. It also provides order and organization
to the operation. With visual systems you will be able to just look
at something and within seconds know if it is right or needs corrective
measures. Visual systems include such things as color-coding, labeling,
setting and marking locations, providing dashboards to track and
establishing kanban – visual queue signals.
5S - focuses on effective workplace organization
to support the best the work process by improving housekeeping and
reducing waste. The five S’s stand for the five first letters
of these Japanese words shown with their corresponding English counterparts.
- Seiri Sort
- Seiton Set in Order
- Seiso Shine
- Seiketsu Standardize
- Shitsuke Sustain
The training is a workshop format where you will
learn on 5S and visual systems including guidelines, measurement
tools and numerous examples. An area of the company will be utilized
to begin the 5S and visual system implementation. Discussion will
include how to establish an ongoing audit program to track and measure
progress.
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Facility Layouts
/ Cellular Flow
One of the largest wastes in an organization is the
plant layout of many brown and green field sites. Over the years
new technology, services and products are introduced and usually
it come down to “where do we stick it”. This method
causes waste. Utilizing the Value Stream Map this classes looks
at how to establish continuous flow, good cell layouts and a facility
layout that is connected to the product family flow.
The training will uses a number of techniques to understand the
current layout and its deficiencies and to design an improved layout.
Taught will be spaghetti or process diagrams, and cut and paste
layout methods may be used to more effectively engage teams. A simply
plant layout can be generate and these be evaluated on reduction
of time and distance, material flow, point of use storage, focused
technology, and support of the Takt time for the product or service.
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Standard Work
Standard work is a formal method to remove operator
variability from the process, improving process control. The goal
is to do a task “The Same Way, One Way, the Right Way, Every
Time”. Establishing standard work instructions formally does
this. Procedures, policies and visual controls define the standard
process and control strategy - what to do in response to out of
control condition.
Standard work ensures process consistency and reduces
operator-introduced variation Methods continuously improved and
documented for efficiency and cost reduction. Statistical Process
Control stabilizes the process and improves quality by appropriate
response to variation.
The training will demonstrate how applying standard
work tools based on the Toyota Production System will achieve tried
and true results. The trainee will learn how to format and write
an excellent standard work instruction and the process to collect
information including using observation, videotaping, documentation
and methods optimization.
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Set Up Reduction /
Quick Change-over
Set up reduction or quick change over is essential
to increase the flexibility of the organization, support smaller
lot sizes, reduce inventory and allow for continuous flow. A changeover
or setup is the duration of time from the last good piece produced
in the previous lot to the first good piece produced in the next
lot at production rate. The goal of set up reduction is to eliminate,
simplify and then automate to reduce this time. Another goal is
to completely eliminate all adjustment and switch them to precision
placements or settings. The last method explored is shifting internal
set up elements to external.
The training is in a workshop format where definitions
of set up is discussed, moving to learning the tools employed in
set up reduction and a set up reduction process. The learning will
then shift to the workplace where a pre-selected set up will be
videotaped and observed. The trainees will then analyze setup /
changeover methods with a goal of eliminating, simplifying or automating
the set up steps to shorten the time. Training team will then brainstorm
solutions and put together an implementation plan. Implementation
tracking can be included in the training.
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