Module 1 - What is Lean and Lean Management?
On day 1 the course will cover a thorough overview of lean concept and practical guide to its key dimensions through cases
Key Topics
- Introduction to Lean
- What is Lean Concept?
- Technical and Cultural Aspects of Lean
- The 3 key dimensions of Lean
Module 2 - Understanding Value Add and Waste
On day 2 the course will cover in depth what kind of activities or jobs which add value and while others just simply add wastes, costs, and time unnecessarily into your organisation
Key Topics
- Waste: Adding Value and Non-adding Value
- Waste definition
- Depth of waste
- The 7 Wastes
- What do you need to do?
- Case Exercises: Ratio & Modular Production
- Linking flexible production with wastes
Module 3 - Key Tool for Waste Reduction
On day 3 the course will cover major concepts of Cycle time, Takt time, and line balancing techniques such as RPW and K&W approaches
Key Topics
- Increasing Capacity without increasing labor cost: Line Balancing
- The concept of Bottle Neck
- Takt Time/Cycle Time
- Techniques of Line Balancing & case exercise
- Skills matrix: increasing worker and process efficiency
Module 4 - What is “Single Minute Exchange of Dies” or SMED and Total Productive Maintenance (TPM)
On day 4 the course will cover SMED and TPM in details, including cases and practical workshop application looking at process changes and equipment efficiency
Key Topics
- Quick Changeover and SMED
- What is it?
- A look at F1 case
- Internal perspectives & External perspectives
- How to reduce changeover time, start up and process end time
- Total Productive Maintenance (TPM) and machine downtime
- Preventive and Predictive maintenance
- The concept of Overall Equipment Efficiency (OEE)
- Equipment loss, Time loss & Quality loss
- The relationship between TPM and Energy Efficiency
Module 5 - Six Sigma
On day 5 the course will cover major quality enhancement tools, the 6 Sigma approach
Key Topics
- Introduction to 3 different dimensions of 6 Sigma
- philosophy
- statistics
- process
- Methodologies of 6 Sigma Improvement Projects: DMAIC
- Design & case
- Measure & case
- Analyze & case
- Improve & case
- Control & case