Day 1

• Overview of lean manufacturing
  • Key concepts
  • Historical background
  • Implementation status
  • Future
• Cell design
  • Cell capacity analysis
  • Cell layout
  • Operator-machine balance analysis
  • Organization of cell teams
  • Performance monitoring
  • Plant layout and logistics
  • Machine movements
  • Finishing touches
  • Dealing with "monuments"
• Assembly line design and logistics
  • Parts supply assurance
  • Movements from suppliers and to customers
  • Movements between and within plants
  • Warehouse operations
  • Economics of assembly
  • The concept of the assembly line
  • Assembly line balancing
  • Assembly station design
  • Part conveyance between stations
  • Buffer sizing
  • Mixed-flow lines

Homework: Case study

Day 2

• Quick setup/SMED/changeover time reduction methodology
  • Motivation
  • Project organization
  • In-Out-Loss (IOL) analysis
  • Generation and analysis of improvement ideas
  • Monitoring and project relaunch
  • Examples of improvement ideas
  • Use of quick changeovers in production planning
• Quality management
  • Control strategy
  • Impact of one-piece flow
  • Mistake-proofing/pokayoke
  • Inspections and tests
• Production planning & scheduling
  • Capacity planning
  • Leveled scheduling/Heijunka
  • The Kanban system
• Implementation
  • Expectation setting
  • Management roles and implementation support structure
  • Depth-first versus breadth-first implementation
  • Typical implementation sequence with the breakthrough strategy
  • Implementation tools
    • Task forces
    • Permanent Kaizen teams
    • Kaizen events
    • Plantwide campaigns
    • Outside consultants
  • Managing operator involvement through guided volunteerism
  • Supplier support
• Discussion: How to put this to work at the plant

: How to put this to work back at the plant