Lean Mastery GES 404 » 60 hours

Overview Description Objectives Outline Prerequisites PC Requirements / Materials Instructor Bio See a Demo

  1. Foreword
    1. Lean Enterprise Defined
    2. How It All Began
  2. The Need for Change
    1. Why Change?
    2. Benefits of Lean
    3. The Evolution to Lean
    4. Touring a Traditional Operation
    5. Lean vs. Traditional Manufacturing
    6. Batch and Queue
    7. The Role of Management
    8. Organization Changes
    9. Resistance
    10. The Role of Education
  3. 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
  4. 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
  5. 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
  6. Transforming the Enterprise
  7. SMED (Single Minute Exchange of Dies)/Quick Change
    1. Audi
    2. Goals
    3. Traditional Concepts
    4. Inventory
    5. Benefits
    6. Rules
    7. Internal vs. 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
  8. 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
  9. 5S
    1. Introduction
    2. Definition
    3. Separate
    4. Sort
    5. Sweep
    6. Standardize
    7. Sustain
    8. Safety
  10. 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
  11. Kanban
    1. Introduction
    2. Definition
    3. Pull vs. 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
  12. Other Lean Tools
    1. Standard Work
    2. Visual Workplace Management
    3. Error Proofing (Poka-Yoke)
    4. Scheduling and Leveling (Heijunka)
    5. Value Selling
  13. Lean and Six Sigma Overview
  14. Lean Accounting Overview
  15. Implementing Lean
    1. Putting it All Together
    2. Lean Road Map
    3. Policy Development
    4. Lean Implementation Plan
    5. Lean Metrics