Lean Manufacturing Breakthrough Techniques - Entrepreneurship Institute Malaysia

LEAN MANUFACTURING
BREAKTHROUGH TECHNIQUES

Continuous improvement and eliminating waste are fundamental principles in Lean Manufacturing systems. Lean Manufacturing is based on setting standards aimed at continuous improvements by all team members through constantly eliminating waste. It is an opportunity to change a flabby waste-filled operation into a toned and muscular manufacturing company.

This program is an antidote to stagnation and to leap beyond today’s best practice. This workshop provides a new manufacturing Diet.

OBJECTIVES

Manufacturing velocity analysis.
Flow system manufacturing by simulation.
Cycle Time reduction by simulation.
Waste reduction by simulation.
Inventory and space reduction by simulation.
Strategic supply chain management.

METHODOLOGY
40% Lectures
60% Simulations

WHO SHOULD ATTEND
Senior manufacturing executive / managers
Operating managers
Materials and/or quality managers
First level supervisors
Manufacturing or industrial engineers
Training managers

WORKSHOP DESCRIPTION
This workshop must be attended if your manufacturing operations need to become more responsive to your customer’s needs. You will be introduced to the many concepts that fall under the umbrella of lean manufacturing, more so you will also get tangible ideas that you can take back to work and implement. For example, you will learn how to reduce cycle time and how to use workflows to develop effective and efficient plant layouts. In addition, you will discover how cellular operation concepts can increase your productivity and deliver results that will enhance your bottom line.

WORKSHOP OUTLINE:

DAY 1

Linkage of Supply Chain Management (SCM) & Lean System
A conceptual framework
SCM for Global competitiveness
Strategic issues in supply chain
Corporate profitability and supply chain
Application of knowledge Management for effective supply chain management in a dynamic business environment.
Traditional Manufacturing Systems
Departmentalization
1st Simulation (10 mins.) (Not Lean)
– participants will take part in some assembly operations performed in a traditional way
– end of simulation calculate the group’s performance
The Lean Principles
Lean Mission
Lean Revolution
Value Revolution
Lean Commitments
Manufacturing Velocity
Choose one of your product, calculate ratio of value added activities to your lead-
time.
The 7 wastes

DAY 1

2nd Simulation (rearrangement of assembly line)
reduction of manpower
elimination of departmentalization
introduction of cell concept
end of simulation calculate the group’s performance
Lean Tools
The flow system
The pull system
Quick changeover
Mistake proofing (Poka Yoke)
3rd Simulation (10 mins)
practice Kanban
reduction of lot size
end of simulation calculate the group’s performance
Elimination of non-value add activities and balance the line
Is inspection value add activity?
Is warehousing a value add activity?
A case study will be introduced
4th Simulation (Lean) (30 mins)
The group to design their own assembly using formula learnt
The groups to eliminate all non-value add activities in their process and set up a
lean line
end of simulation calculate the group’s performance
participants to compare the results of 1st, 2nd, 3rd and 4th. simulation to make an evaluation of what is value add and non-value add in your organization.

Program Code: 2-1000-02