Lean Mastery

GES 404 -- 60 hours

Course Outline

I. Foreword

1. Lean Enterprise Defined
2. How It All Began

II. The Need for Change
1. Why Change?
2. Benefits of Lean
3. The Evolution to Lean
4. Touring a Traditional Operation
5. Lean v. Traditional Manufacturing
6. Batch and Queue
7. The Role of Management
8. Organization Changes
9. Resistance
10. The Role of Education

III. Lean Theory
1. Overview
2. Waste
3. The Types of Waste
4. Provide Value
5. Radical Change
6. Continuous Incremental Improvement
7. Lean Elements
   1. Value
   2. Value Stream
   3. Flow
   4. Pull
   5. Perfection
8. Lean Rules
   1. Standard Work
   2. Limit Material Movement
   3. Limit People Movement
   4. Educate Everyone
9. Lean Tools Overview
   1. Kaizen
   2. 5S
   3. TPM
   4. SMED
   5. Process Mapping
   6. Takt Time
   7. Line/Work Balancing
   8. Kanban
   9. Mistake Proofing
   10. Autonomation
   11. DFMA
   12. Visual Workplace
   13. 5 Why
   14. One-Piece-Flow
   15. Spider Charts
   16. Spaghetti Charts
   17. U-Shaped/Continuous Flow Cells
   18. Rabbit Chase
   19. Six Sigma
   20. Focused Factory

IV. Kaizen
1. Kaizen Defined
2. Philosophy
3. 10 Principals
4. Problem Selection
5. Guidelines
6. Value-Added, Non Value-Added, Non-Value-Added Required
7. Manufacturing Kaizen
   1. Batch and Queue
   2. Manufacturing Kaizen goals
   3. Manufacturing Kaizen aspects
   4. Manufacturing Kaizen presentation
   5. Summary
8. Administrative Kaizen

V. Value Stream Mapping
1. VSM Defined
2. Purpose of VSM
3. Technology Used
4. The Current State Map
5. The Future State Map
6. Strategy
7. Getting Started
8. The Team
9. Developing a VSM
10. VSM Approach
11. Definitions and Icons

VI. Transforming the Enterprise

VII. SMED (Single Minute Exchange of Dies/Quick Change
1. Audi
2. Goals
3. Traditional Concepts
4. Inventory
5. Benefits
6. Rules
7. Internal v. External Activities
8. Methodology
9. Observe and Document Current Process
10. Separate Internals from Externals
11. Develop Plan
12. Observe and Document New Process
13. Standardize New Process
14. Celebrate

VIII. TPM (Total Productive Maintenance
1. Introduction
2. Definition
3. Alternatives
4. Prevention Principles
5. Obstacles
6. Types of Breakdowns
7. Deterioration
8. How TPM is Implemented
9. Overall Equipment Effectiveness (OEE)
10. Calculating OEE
11. The Six Big Losses
12. Types of Maintenance
    1. Preventive
    2. Breakdown
    3. Corrective
    4. Predictive
    5. Maintenance Prevention
13. TPM Tools
14. Autonomous Maintenance
15. 7 Steps to Autonomous Maintenance
16. Skills Training
17. TPM Strategy

IX. 5S
1. Introduction
2. Definition
3. Separate
4. Sort
5. Sweep
6. Standardize
7. Sustain
8. Safety

X. DFMA (Design for Manufacture and Assembly
1. Definition
2. Traditional Approach
3. Concurrent Engineering
4. DFMA Principles
5. DFMA Rules
6. Why DFMA?
7. Design Techniques
8. Design Process
9. Design for Six Sigma Overview
10. DFMA Benefits
11. Product Release

XI. Kanban
1. Introduction
2. Definition
3. Pull v. Push Systems
4. Function
5. Applications
6. Information Flow
7. Types
8. Calculations
9. Information Requirements
10. Manufacturing Rules
11. Planner Rules
12. The Role of MRP
13. Electronic Systems
14. Inventory Carrying Costs

XII. Other Lean Tools
1. Standard Work
2. Visual Workplace Management
3. Error Proofing (Poka-Yoke)
4. Scheduling and Leveling (Heijunka)
5. Value Selling

XIII. Lean and Six Sigma Overview

XIV. Lean Accounting Overview

XV. Implementing Lean
1. Putting it All Together
2. Lean Road Map
3. Policy Development
4. Lean Implementation Plan
5. Lean Metrics