Lean Manufacturing For Quality Improvement

Course overview

The Lean Manufacturing Course focuses on applying lean manufacturing concepts in a methodical way to enhance a production system. The majority of lean programs concentrate on the principles rather than the application.

The issues faced by a manufacturing practitioner who wants to start implementing Lean but are unsure of where to begin or how to use Lean tools have been addressed in this highly practical course. Manufacturing case studies, examples, pertinent tools, templates, and their implementation are the main points of emphasis. This course makes the connection between lean approaches and modern production techniques.

Why Take a Course on Lean Manufacturing? Regardless of their existing position, all manufacturing professionals should take a lean manufacturing course. All they need is a desire to use lean manufacturing methodology and lean technologies to improve their organization’s processes and systems. Lean aims to increase customer value by cutting waste in the production process and plant.

Participants will gain comprehensive knowledge of lean manufacturing technologies and how to apply them to enhance productivity, efficiency, utilization, and process velocity by completing this Training Bee training course.

Using lean tools and templates, the course will assist you in gaining the knowledge and abilities required to apply the technique. You will gain the necessary confidence to apply Lean Manufacturing Principles in your plant by completing this course.

Introduction

The purpose of the extensive training program known as the Lean Manufacturing Course is to provide participants with the knowledge, skills, and resources they need to revolutionize manufacturing operations and procedures. Lean Manufacturing, which has its roots in the idea of continuous improvement, strives to maximize value for customers while reducing waste and increasing efficiency. An organized framework for comprehending and using Lean principles in manufacturing settings is offered by this course.

In conclusion, the goal of the Lean Manufacturing Course is to provide participants with the information and abilities needed to spearhead revolutionary modifications to manufacturing procedures. Participants can help the industrial industry achieve increased productivity, decreased waste, and long-term improvement by adopting the Lean principles.

We are The Training Bee, a global training and education firm providing services in many countries. We are specialized in capacity building and talent development solutions for individuals and organizations, with our highly customized programs and training sessions.

Learning Objectives

Upon completing Lean Manufacturing Course, participants will be able to:

• Thorough understanding of lean manufacturing tools and how they affect product costs and plant productivity
• The necessary abilities to comprehend and/or assess lean implementation maturity in your plant’s various departments and processes in order to look for any gaps and provide appropriate recommendations
• Methods and instruments in the endeavor to implement lean principles within the company
• A feeling of accomplishment for facilitating the expansion and scalability of the organization, which in turn showcases potential and skill and fosters new opportunities for positions and responsibilities
• The ability to adjust to change without letting it impair one’s effectiveness as an individual, as a team, or as an organization
• The aptitude and capacity to produce work of a higher caliber while establishing dependability and reputation

Our Unique Training Methodology

This interactive course comprises the following training methods:

• Journaling – This consists of setting a timer and letting your thoughts flow, unedited and unscripted recording events, ideas, and thoughts over a while, related to the topic.
• Social learning – Information and expertise exchanged amongst peers via computer-based technologies and interactive conversations including Blogging, instant messaging, and forums for debate in groups.
• Project-based learning
• Mind mapping and brainstorming – A session will be carried out between participants to uncover unique ideas, thoughts, and opinions having a quality discussion.
• Interactive sessions – The course will use informative lectures to introduce key concepts and theories related to the topic.
• Presentations – Participants will be presented with multimedia tools such as videos and graphics to enhance learning. These will be delivered engagingly and interactively.

Training Medium

This Lean Manufacturing Course training is designed in a way that it can be delivered face-to-face and virtually.

Course Duration

This training is versatile in its delivery. The training can be delivered as a full-fledged 40-hour training program or a 15- hours crash course covering 5 hours of content each day over 3 days

Pre-course Assessment

Before you enroll in this course all we wanted to know is your exact mindset and your way of thinking.
For that, we have designed this questionnaire attached below.

• What does lean manufacturing mean to you?
• Give a brief explanation of the main Lean principles.
• Do you possess any training or real-world experience in Lean?
• Producing previously? If so, kindly give a succinct synopsis.
• List the value, value stream, flow, pull, and perfection as the five main tenets of lean manufacturing.
• Describe the ways in which these ideas help to reduce waste in industrial processes.
• Which of the seven categories of waste in industrial processes can you name with examples? Give a minimum of three instances.
• Explain the meaning of a value stream map and its application to lean manufacturing.
• Have you ever participated in or produced a value stream map? If so, kindly give a succinct explanation.

Course Modules

This Lean Manufacturing Course covers the following topics for understanding the essentials of the Agile Workplace:

Module 1 – Overview of Lean Manufacturing

• Constant Enhancement
• Improvement Theories and Approaches
• The Lean Principles
• Contemplating Revolution
• Gaining Customer Focus: Recognize Value

Module 2 – As per Lean, MUDA, MURI, and MURA

• MUDA
• MURI
• MURA

Module 3 – 5S

• The Five S
• 5S Instruments
• Yoke Poka
• Customized Procedures
• Jidoka

Module 4 – TPM

• Motion Analysis
• Appraisal of Value
• Analysis of 5W and 2H
• Five Reasons Analysis

Module 5 – Assessing and Sorting Enhancements

• Radar Chart: Monitoring Developments in Twenty Domains
• All-around Equipment Efficiency (OEE): Performance, Availability, and Quality
• Time Allotted for Work
• Time of Loading

Module 6 – Optimizing Material Flow with Proper Plant Layouts

• Recognizing Various Manufacturing Industry Types
• Comprehending Various Layout Types
• Four Indices and Justifications for Changing the Design
• A Six-Step Guide to Optimal Layout
• Eight Things to Take Into Account for a Good Layout

Module 7 – Material Flow and Cellular Layout Design

• Material Flow in Mass Production and Assembly Lines
• Justification for Cell Layout
• Basic Nomenclature for Cell Design

Module 8 – Essentials for Improving the Workplace

• Arranging and cleaning
• Making Sense of the System
• Enhancement Group Exercises
• Cutting Down on Inventory
• Rapid Technology Transition

Post-course Assessment

Participants need to complete an assessment post-course completion so our mentors will get to know their understanding of the course. A mentor will also have interrogative conversations with participants and provide valuable feedback.

• Give an outline of the procedures you would follow to perform a value stream mapping analysis on a particular process or product.
• Think back on a Kaizen experience or an ongoing improvement project that was covered in class. What were the main lessons learned, and how may your company implement a similar strategy?
• Talk about how you would apply one of the five S’s (sort, set in order, shine, standardize, and sustain) in your place of business.
• Create a strategy for integrating Just-in-Time (JIT) manufacturing into a production process. What advantages do you anticipate, and how would you assess whether the deployment was successful?
• Provide tactics for getting staff members involved in Lean projects. How can a culture of involvement and ongoing development be established on the shop floor?

Lessons Learned

Holistic Perspective on Efficiency: Lean Manufacturing promotes an all-encompassing perspective on efficiency. For optimal productivity, the entire value stream must be optimized rather than simply a few selected procedures.

Continuous Improvement as a Culture: The training places a strong emphasis on the idea that Lean is a journey rather than a one-time endeavor. Companies should encourage a culture in which all staff members actively seek for and remove waste.

Frontline Employee Empowerment: Lean Manufacturing gives frontline employees the tools they need to actively participate in process improvement. Their recommendations and insights are helpful tools for locating and fixing problems.

Waste Identification and Elimination: Participants get knowledge about how to recognize and classify different kinds of waste in systems and processes. The training places a strong emphasis on how to improve overall efficiency by methodically getting rid of waste.

Use of Tools and Techniques Strategically: There is no one-size-fits-all approach when it comes to lean tools and techniques. A strategic approach, along with the appropriate tool selection and application based on the particular demands and difficulties of the company are necessary for successful implementation.

Customer-Centric Focus: Providing value to customers is a key component of lean manufacturing. Through the creation of goods and services that actually add value, participants learn how to match procedures with the demands and expectations of customers.