Lean Manufacturing Course

A-B Tech and Eaton Electrical Group

________________________________________________________________________

Lean Manufacturing Course Agenda

(March 13-17, 2006)
Enka Campus, Hayes 128
Each module is 3 and hours. Total course length is 37.5 hours. Morning session is
8:30 am to noon. Afternoon session is 1:00 pm to 4:30 pm.
This is an overview course for the Lean Manufacturing discipline. It focuses on the tools,
techniques, concepts and principles of Lean. While most of the emphasis is on the
manufacturing environment, examples from administrative functions are also used to
explain key concepts. This is not a course on the leadership and management roles and
responsibilities required to successfully implement Lean. Lean implementation is a
MAJOR change initiative and as such, senior leadership must be completely committed
to achieve success. All best practices in leading significant change efforts apply to
Lean; however, this is not a course on leading major change initiatives. Participants will
need to seek that knowledge elsewhere.
Module 1: Introduction to Lean and Factory Simulation (short version)
Day 1: Morning Session
This is an introduction to the basic principles and concepts of Lean Manufacturing.
Instructors will lead participants through a basic factory simulation (hands-on) that will
demonstrate how Lean can be used to dramatically improve productivity. Topics include:
a.
b.
c.
d.

An overview of Lean principles/concepts/tools.

The 7 Wastes, their causes and the effects.
Stockless Production (Video from HP)
Factory simulation (hands-on, short demonstration)

Module 2: The Tools of Lean Manufacturing: Overview

Day 1: Afternoon Session
The Lean tools explored throughout the remainder of the course are introduced in this
module. The SME video, Lean Production at Miller SQA, will be used to introduce
this module. In addition to the video, presentation topics include:

a.
b.
e.
c.
d.
f.
g.
h.

Value Stream Mapping (VSM).

5S.
Pull Systems.
Standardized Work.
Continuous Flow.
Error Proofing.
Setup Reduction.
Total Productive Maintenance (TPM).

Module 3: Learning to See: Value Stream Mapping Current State

Day 2: Morning Session
________________________________________________________________________
Page 1

Lean Manufacturing Course

A-B Tech and Eaton Electrical Group

________________________________________________________________________
Participants will learn the basics of Value Stream Mapping (VSM) and then will apply
these concepts to build a Current State Map. This module is based on the Workbook,
Learning to See, by the Lean Enterprise Institute. VSM is a tool that helps people to see
and understand the flow of material and information as a product makes its way through
the value stream. The SME video, Mapping Your Value Stream, will be used during
this module. In addition to the video, topics include:
a.
Preparation for building a Current State Value Stream Map.
b.
How to build a Current State Map (principles, concepts, loops, and
methodology).
c.
Application to the factory simulation scenario.
Module 4: Factory Simulation Phase 1: Initial Configuration and Current State
Mapping
Day 2: Afternoon Session
The entire module is devoted to conducting the first phase of a factory simulation.
Participants will use everything learned so far in the course to conduct a pre-set factory
simulation, determine data requirements for process analysis, set up and execute a data
collection plan, analyze the data, and construct a Current State Map of the Phase 1
process configuration. Participants will draw heavily upon the techniques studied in the
Learning to See workbook from Module 3. The Current State Map developed in this
module will be used as the jumping off point for subsequent modules and for Phase 2 and
3 of the factory simulation.
Module 5: 5S and Pull Systems
Day 3: Morning Session
5S is the foundation for a disciplined approach to improving and standardizing the
physical condition of the work areas (shop floor as well as front office). Participants will
learn the concepts of 5S and effective implementation techniques. Topics include:
a.
b.
c.
d.
e.
f.

5S Sort.
5S Straighten.
5S Shine.
5S Standardize.
5S Sustain.
Implementation of 5S.

The SME videos, Kanban Systems and Lean Tooling in Action, will be used in the
exploration of Pull Systems. The focus of this portion of the module will be on changing
from a PUSH process to a PULL process so that you make only what the customer is
pulling from your production system. Topics include:
a.
Pull versus Push production systems.
b.
The key elements of Pull Systems.
c.
Pull System Kanban (4 types)
________________________________________________________________________
Page 2

Lean Manufacturing Course

A-B Tech and Eaton Electrical Group

________________________________________________________________________
d.
Pull System Load Leveling
Module 6: Standardized Work and Continuous Flow Manufacturing
Day 3: Afternoon Session
The Standardized Work materials focus on designing the optimum combination of
operators, machines and materials to ensure that production tasks are completed the same
way every time with minimum waste. In the Continuous Flow materials, participants will
learn how manual and machine operations can be linked to increase efficiency while
minimizing transport and delay. These concepts will then be used to explore a step-bystep approach to design and implement a flow line (cell). The SME video, The Visual
Factory, will be used in this module. In addition to the video, topics include:
a.
Standardized Work Flow concepts.
b.
Documenting and sustaining standard work practices.
c.
Implementation techniques for Standardized Work.
d.
Concepts and principles in setting up and implementing a continuous flow
line (cell).
Module 7: Learning to See: Value Stream Mapping Future State
Day 4: Morning Session
This module is based on the workbook, Learning to See, by the Lean Enterprise Institute
It introduces the principles and techniques used in building a Future State Map. Topics
include:
a.
Key questions in building the Future State Map.
b.
Process tips in building the map and analysis of the customer loop,
supplier loop, manufacturing loop and information loop that make up the map.
c.
Example of completed Future State Maps.
d.
Application to factory simulation.
Module 8:
Factory Simulation Phase 2 and 3 -- Future State VSM.
Day 4: Afternoon Session
This module builds on the Learning to See modules and on Phase One of the factory
simulation introduced in Module 5 of the course. The simulation requires the participants
to use all the tools and concepts that theyve learned about Lean up to this point to
develop the Future State Value Stream Map based on the already developed Current State
Map and on the process analysis done through the use of the lean tools. The participants
will:
a.
Conduct an analysis of all the data developed during the development of
the Phase 1 Current State Map.
b.
Based on the analysis, build a Future State VSM for Phase 2 of the
simulation as directed by the instructor, implement, collect data, analyze and
present.
________________________________________________________________________
Page 3

Lean Manufacturing Course

A-B Tech and Eaton Electrical Group

________________________________________________________________________
c.
Based on the outcome of Phase 2, develop a final Future State VSM
(Phase 3), re-run the simulation, collect data, analyze and report findings.
Module 9: Error Proofing and Setup Reduction
Day 5: Morning Session
The Error Proofing materials in this module, including the SME video, Mistake
Proofing, provide a systematic approach to preventing potential defects from reaching
the customer. Topics include:
a.
b.
c.
d.

Understanding error proofing concepts and principles.

How to apply error proofing to products and processes.
Poka Yoke devices and systems.
How to implement and continuously improve error proofing.

In the Setup Reduction materials, which include the SME video, Quick Changeover for
Lean Manufacturing, participants will learn a 5-step approach to identifying
opportunities for and drastically reducing equipment setup time. Emphasis will be on
how Setup Reduction allows for reducing batch sizes without increasing production costs.
Topics include:
a.
b.
c.
d.

Understanding what Setup is and the 5 step approach.

Why Setup Reduction is necessary for Lean.
How to implement on individual setups.
How to implement and sustain throughout the plant.

Module 10: Total Productive Maintenance (TPM) and the Shop Floor
Day 5: Afternoon Session
TPM is an equipment operating philosophy that aims at extreme productivity by relying
on team-based activities to completely eliminate equipment breakdowns, defects, and
other manufacturing losses. The SME video, Total Productive Maintenance, is
included as part of this module. Participants will learn how to ensure high equipment
reliability, maintainability and performance. Topics include:
a.
Bringing equipment to optimal condition to ensure a high level of
availability.
b.
Developing a maintenance program for the life of the equipment.
c.
Ensuring continuous improvement.
d.
Training operators and maintenance personnel for TPM.
e.
Involving all departments and all levels through support, participation and
ownership.
f.
Implement objective measurement system (OEE) to identify action items
and monitor progress.
g.
Improvement examples from TPM projects.

________________________________________________________________________
Page 4