Course Overview

A three day practical lean manufacturing training course suitable for senior executives/managers looking to implement lean manufacturing into their businesses.

Where this course differs from other lean courses in this field is that it focuses on developing management strategies for ‘winning the hearts and minds’ of the workforce as well as developing a lean implementation plan for their business to create true sustainability.

The content of this training course has been developed following the successful implementation of the lean techniques, concepts and strategies used in this course by companies throughout the UK, with the help of our course tutors.

Why introduce Lean Manufacturing?

• Increased Customer Satisfaction –more repeat business
• Reduced Waste –shorter lead times, lower costs
• Improved Profitability
• Improved Process Control –more right first time
• Company Wide Team Work - breaking down functional barriers to success

What you will learn

At the conclusion of the lean tools session each delegate should be able to:-

• Implement and maintain a departmental wide visual 5S programme
• Recognise ‘waste’ and non-value added activities throughout their operation
• Introduce a basic pull scheduling system e.g. Kanban
• Design and set up a lean manufacturing cell
• Identify the various types of mistake proofing devices and how they could be used in a zero quality control system
• Follow a standard process to significantly reduce machine change-over times
• Identify a programme to maintain production equipment
• Generate value stream maps of their own manufacturing processes to highlight waste and suggest improvements

Course Content

Introduction – Setting the Scene

• Introduction to Lean – What is it all about?
• Definitions – Jargon Busting
• What benefits can we realistically expect from a company wide lean programme?

People – “Winning the Hearts and Minds”

What is expected of a manager in a lean manufacturing environment?

• Roles
• Responsibility
• Accountability
• Ownership

• How to bring about a lean environment by effective communication

• How to create a lean culture with self-managing, empowered teams

• Initiating Kaizen activities- making it work for your business

• Breaking down cross functional barriers

• Dealing with objections from other parties

• Getting the ‘cynics’ on board the programme

• Knowing where to start

Lean Tools – An Overview

A practical session where interactive business ‘games’ are used to demonstrate lean tools in action including:

• 7 Wastes
• 5S and Visual Factory
• Kanban
• Cellular Manufacturing
• Zero Quality Control, Source Inspection & Poka Yoke
• Single Minute Exchange of Dies (SMED)
• Total Productive Maintenance (TPM)
• Lean Office
• Value Stream Mapping

The Implementation Plan – “Incremental and measurable change”

• How to generate a management lean implementation plan
• Selection & Introduction of Key Performance Indicators (KPIs)
• How to sustain the lean project – to ensure its not perceived as just another fad
• Phased Introduction supported by pilots and reviews
• Regular, objective review of progress, inhibitors and milestones

Workplace Overview – IN HOUSE COURSE ONLY

This session involves spending time as a group ‘walking the job’. It’s about ‘learning to see’ the waste in your business. We accomplish this by spending time in each of your delegates’ departments, teaching them to ‘see’ the areas of waste and discuss improvements which could be made by implementing a lean philosophy.

Following this activity we carry out a group ‘brainstorming’ session to identify possible pilot projects, areas of concern and to generate a lean implementation plan by work area. This will culminate in drawing a value stream map of one of your processes to demonstrate how to visualise current issues and how to use this process to initiate improvements.

The how to implement lean manufacturing training course is limited to a maximum of twelve delegates. Course costs cover the three training sessions, a comprehensive set of course notes, lunch, refreshments and an attendance certificate.

This is a non-residential training course. This course can be delivered in-house if required.

For further information contact Aster Training on 01296 720281 for a Free Consultation to discuss your training requirements. Cost is exclusive of VAT which is chargeable at the current rate. Prices are correct at the time of publishing, but may be varied in line with market conditions from time to time.