• Overview of lean manufacturing for machine shops
  • Historical background
  • Key principles
• Analysis techniques
  • Product-Quantity analysis
  • Takt time analysis
  • Materials and information flow mapping
  • Shop floor observation techniques
  • Analysis of warehouse storage and retrieval operations
• Cell design
  • Examples of cells
  • Machining process development
    • Target automation level
    • Process design, cutting tools and parameters as speed and feed
    • Alternatives of process combination and  machines selection
  • Cell capacity analysis
  • Layout based on material flows and people movements, and layout review techniques
  • Operator job design through work combination charts
    • Use as an analysis tool
    • Use as a communication/instruction tool
  • Cell teams
  • Performance monitoring
  • Machine movements
  • Finishing a cell
  • Operator instruction sheets
• Setup time reduction
  • Motivation: Use of quick changeovers in production planning
  • Project organization
  • In-Out-Loss analysis
  • Generation and analysis of improvement ideas
  • Examples of improvement ideas
  • Quality improvement due to setup time reduction

Homework: Case study of allocating work between old and new machines with overlapping capabilities

Day 2

• Equipment selection and automation
  • Example: 5-axis machining center versus 3-axis machine with progressive fixture
  • Example: Allocating work among machines with overlapping capabilities
  • Machines for rate work versus response work
  • The seven steps of automation
  • What to do about legacy automated systems
  • Cost-justification for new machine acquisition
• Maintenance
  • Characteristics of maintenance activities
  • Content of maintenance work and its evolution
  • Maintenance organization
  • All employee involvement from 5S to TPM
• Quality management
  • Compliance with standards versus quality improvement
  • Positioning of statistical methods, one-piece flow and mistake-proofing
  • Mistake-proofing examples from daily life and the shop floor
  • Organization of inspection and test operations
• ERP
  • From MRP to ERP
  • Using ERP systems in a JIT/flow manufacturing environment
• Production planning and scheduling
  • Takt-driven production and leveled sequencing
  • Machine shop production planning and scheduling
  • Timetables
  • Role and function of "Production Planning”