Lean Manufacturing

Course Objectives

• To introduce and learn the core TPS Lean Manufacturing practices
• To identify opportunities of wasteful processes that should be eliminated
• To improve cycle-time and add value to the process and products
• To operate and sustain manufacturing in a continuous improvement mode
• To improve overall Quality, Productivity, Cost, Profit, Morale & Customer Satisfactions

Target Audience

• Production, Engineering, Maintenance & Planning
• Managers, Executives & Supervisors
• Those who need to learn the techniques in improving cycle-time

Methodology

This session will be interactive and uses diverse teaching methods in which the trainer will use interactive lecture and slide presentation to cover the modules stated below.

Course Modules

Module 1: Introduction

• Context Setting
• Course Objectives & Benefits
• Discussion : Common Issues

Module 2: The Iceberg Is Melting

• The Iceberg is Melting
• Competitive Business Scenarios
• The world is constantly changing & improving

Module 3: The Inevitable Force

• What had changed & improved
• Changes & improvement around us today
• Choices : Improve or Obsolete

Module 4: TPS Lean System

• Toyota Production System
• Creating Customer Value
• Approach to Lean Thinking

Module 5: Lean Basic Concepts

• Flow
• Pull System
• Kanban System

Module 6: 3 Aspects of Lean Practices

• 5S
• 7 Waste
• Value Stream Mapping

Module 7: 5S as Lean Foundation

• The 5S Approach & Benefits
• The 5S Method & Key Principles
• Duties & Responsibilities

Module 8:  The 7 Waste in Lean

• Defining Lean & Waste
• The 7 Waste
• The 7 Waste Analysis