This is a typical training course structure
Programme Introduction
Understand the principles of Lean Thinking and how these principles can be implemented in your organisation. Appreciate how Lean Manufacturing can lower the cost of production by changing the processes used to manufacture the product by transforming time spent on "non value adding" activities into "value adding" activities.
Module Content
The Steps to Lean Manufacturing -
Elements covered include:Identification of the 8 forms of waste Understand the principles of Takt & Cycle Time The concept of Plan Do Check Act (PDCA) & Standardise Do Check Act (SDCA) Workplace organisation & The 5S's Visual management techniques Poka Yoke (One-Way Fit) Kanban ('Pull' verses 'Push' Systems) SMED - Single Minute Exchange of Dies Single Piece Flow Standardising Processes 5 S's of Workplace Organisation
Programme Introduction
One of the easiest ways to determine a company's attitude towards improvement activities is simply to walk around the company and review the housekeeping practices. Based upon our experience this programme will help establish behaviour, that when adopted, is the basis of working smarter not harder. Like many concepts, the 5S's can be interpreted narrowly or broadly depending on the circumstances of their use.
Module Content
The 5S's approach to workplace organisation is as relevant and beneficial in all areas of an organisation. This programme is designed so that delegates Understanding the basics principles of the 5S's is significantly increased
Elements covered include:
How to implement the 5S's successfully into the workplace Identifying why this programme is more than a "Housekeeping" initiative Getting a clear understanding of the importance of an effective working environment and the equipment that is used within it Sustaining the changes pro-actively Making plans for the next step towards World Class Manufacturing How to promote employee ownership of their own working environment and development of the continuous improvement culture Integration with all Lean Tools Quick Changeover Principles
Programme Introduction
Reducing downtime like changeover times is a fundamental requirement of Lean Manufacturing. By understanding the principles and practices of the Single Minute Exchange of Die (SMED) system organisations will be able to cut changeovers by up to 50% with very little expenditure, and even further with the modification of tooling and fastening systems. The principles can be applied to any changeover operation and aims to reduce the overall downtime for a complete changeover.
Module Content
Delegates will gain an understanding of the methodology required to achieve quick changeovers and how the dramatic reduction in downtime that can be achieved, between the last good part to the first good part from the next component to be produced. Elements covered include:
History of quick changeover development Establishing economic batch sizes Elements of set up and delays encountered during changeovers Eliminating "wastes" - set up, replacement and adjustment wastes Understanding "internal" and "external" elements in a changeover Importance of starting with "low cost or no cost" approach Reducing waste in parts and materials used in changeovers Raising utilisation of equipment "On-Stream" and "Off-Stream" activities Error Proofing, Mistake Proofing, or Poke Yoke
Programme Introduction
Mistake Proofing, or Poke Yoke, is a team-oriented approach to preventing errors from being produced. The use of Mistake Proofing removes the burden of inspection from the operator and allows the operator to focus solely on producing perfect products.
Module Content
At the completion of this training program, the participants will be able to understand the impact of cost of quality on company profits. Participants will understand the basics of error proofing and how to implement an effective mistake-proofing program. Elements covered include:Building quality into the process Cost of Quality Causes and Types of Defects The Mistake Proofing Process The Zero Defect Strategy - Selected Inspection, Correcting Function, Check Methods Error Proofing Devices Warnings versus Controls Applications Total Productive Maintenance (TPM)
Programme Introduction
Total Productive Maintenance (TPM) is a programme for fundamental improvement in the performance and productivity of any plant / machine. The programme will focus on giving the participants the understanding of the need to move from Preventative Maintenance, through Productive Maintenance to Total Productive Maintenance. Emphasis will also be placed on Autonomous Maintenance and OEE calculations.
Module Content
Realise the importance of optimising overall equipment effectiveness (OEE) i.e. equipment availability. At the end of this workshop delegates should be able to identify opportunities for TPM in their company, and apply a range of tools & techniques for improving OEE. This will help you develop a proactive strategy for optimising the effectiveness of production equipment. Elements covered include:
Introduction to TPM Why TPM Aims of TPM Identification of areas of waste and losses Calculating and measuring OEE Small group activities, autonomous maintenance and focused improvement Contaminates and sources of contaminates Implementation steps Continuous Improvement Activities Identification of the "Six" Big losses Understanding the 5 Pillars of TPM Integration with the 5S's and SMED KANBAN / Shop floor inventory management system
Programme Introduction
The concept behind the Kanban system is to reduce costs in high volume production lines. One way to do this is to smooth and balance material flows by means of controlled inventories. A Kanban system allows an organization to reduce production lead time which in turn reduces the amount of inventory required.
Module Content
Through practical demonstrations and instructor led sessions, this course examines the techniques of KANBAN and how they can be applied in the workplace. Elements covered include:
Practical concepts, objectives, principles and the scope of JIT, and its impact. Production considerations and the formulas to sustain change. Calculating minimum stock levels. Detection and identification of excess stock. Understanding the principles of Kanban, its varying forms and the pitfalls of zero stocking policies. Understanding the procedures necessary to maintain operating efficiencies with minimum stock. An understanding of waste elimination and the concept of Value Adding and Non-Value Adding. Supply-chain alignment and integration. >Cellular Manufacturing
Programme Introduction
This hands-on course teaches participants how to get people and machines to work together as efficiently as possible to reduce lead times, minimize work-in-process, optimise floor-space usage, and improve productivity.
Module Content
Delegates who attend this programme, will quickly understand that by using the one piece flow principle combined with the concept of U-shaped cells and parallel lines, it will allow people in the cell more access to more processes, increasing their potential productivity. Elements covered include:
Traditional manufacturing versus Cellular Manufacturing Designing U-shaped and Parallel Line Cells One-piece flow versus Batch production Characteristics of One Piece Flow Pull systems versus Push systems Pull system characteristics Examples of Takt Time calculations Measuring & Balancing to Takt Time Understanding work combination tables Flow Process Analysis Structured Problem Solving
Programme Introduction
Effective structured problem solving skills are a basic requirement for any job. Having an efficient means of identifying and eliminating the root cause and preventing recurrence whilst minimising the time off the job are the aims of this course.
Module Content
The course is designed to provide you with the analytical and procedural information you need to successfully understand, describe, and participate in the SPS problem-solving process. SPS consists of nine steps. These steps are used to identify, define and solve problems objectively and prevent similar problems from happening again.
Recognising the importance of assessment and verification at each step of the problem solving process, accurate root cause analysis and the determination of permanent corrective actions to prevent recurrence. The 9 step process is:Step 1 - Establish the Team Step 2 - Describe the Problem Step 3 - Containment Action Step 4 - Define & Verify Root Cause Step 5 - Select Permanent Corrective Action Step 6 - Verify & Implement Permanent Corrective Action Step 7 - Prevent Recurrence Step 8 - Capture Process Improvement Opportunities Step 9 - Congratulate the Team
Make a comment / ask a question about this in the Activa Consulting Community